Application of FEM in

Automotive Structure Design

HongTae Kang
University of Michigan-Dearborn
 Introduction
• Automotive Systems Engineering (ASE)
Program in University of Michigan-Dearborn

• AENG 550: Vehicle Chassis and Body Design

• AENG 551: Application of Finite Element

Method in Automotive Structure Design

• Summary
 ASE Program in UM-Dearborn
• Area I. Core Courses (12 credit hours)
– Required Core Courses
AE 500 The Automobile - An Integrated System
AE 587 Automotive Manufacturing Processes

– Elective Core Courses (any two)

AE 502 Modeling of Automotive Systems
AE 505 Digital Systems and Microprocessors
AE 510 Vehicle Electronics I
AE 541 Introduction to Automotive Dynamics
AE 545 Vehicle Ergonomics I
AE 547 Automotive Powertrain I
AE 581 Materials Selection in Automotive Design
AE 583 Project Management and Concurrent Engineering
AE 596 Internal Combustion Engines I
 ASE Program in UM-Dearborn
• Area II. Concentration Courses (12 credit
hours)
– INDUSTRIAL AND MANUFACTURING
CONCENTRATION
– ELECTRICAL AND COMPUTER CONCENTRATION
– MECHANICAL ENGINEERING CONCENTRATION
– AUTOMOTIVE MATERIALS CONCENTRATION

• Area III. Capstone Project/Thesis (6 credit

hours)
 AENG 550
• Vehicle Sub-systems Design
– Suspension design
– Brake design
– Wheel and tire

• Vehicle Structure Design

– NVH
– Durability
– Crashworthiness
 AENG 551
• Class
– Basic Theory of Finite Element Method
– Textbook: A First Course in the Finite
Element Method
– By Daryl L. Logan
• Lab
– Pre/post-processor
– MSC Nastran
– MSC Fatigue
 AENG 551
• Basic Finite Element Theory

– Rod
– Beam
– Shell
– Solid
 AENG 551
• Lab
– Pre/Post-processor
– Static stress analysis
– Stiffness analysis
– Normal mode analysis
– Frequency response analysis
– Fatigue analysis
 AENG 551
• Pre/Post-processor
– HyperMesh 7.0
– Creating collectors
– Importing CAD file and Fixing geometry for
meshing
– Generating mid-plane from solid geometry
– Meshing shell
– Setting up MSC Nastran input file
 AENG 551
• Static stress analysis
– Project 1: Rim-Roll Flex Test

SAE 2005-01-1072
 AENG 551

• Stiffness analysis

– Bending stiffness

– Torsional stiffness
Body Bending Stiffness

Constrained
1-6
Body Torsional Stiffness

F 1-6
F 1-6
 AENG 551
• Normal mode analysis
 AENG 551

• Fatigue Analysis Procedure

RLDA System Material
Model Data

Mechanical
Mechanical Fatigue
Fatigue
Component Load Histories
Simulation
Simulation Analysis
Analysis

FE FE
FE Stresses & Strains
Model Analysis
Analysis
 AENG 551
• Fatigue analysis using MSC Fatigue
 Summary
• Basic FEM theory and practical FE tools

• Brief knowledge about vehicle structural

Analyses

• Many students utilize FEA for their

Capstone projects

• Jobs in vehicle design

Dr. HongTae Kang: htkang@umich.edu