EUR HTC2008 Inoue English UPweb

2nd European HyperWorks Technology Conference Strasbourg September 30th –October 1st, 2008
Door slam simulation for durability analysis with

Multibody Dynamics
○ Takeshi Inoue Hiroaki Hoshino

TOYOTA AUTO BODY CO.,LTD.
Altair Engineering
Computer Aided Engineering Div.
September 30th –October 1st .2008

Company Profile TOYOTA AUTO BODY CO.,LTD.
Toyota Auto Body is developing and

producing minivans, SUVs and commercial
vehicles as a main Toyota affiliate.
Products Line-up
・ALPHARD ・Freezer vehicle
・NOAH/ VOXY ・Container van
・ESTIMA ・Load labor-saving vehicle
・ESTIMA HYBRID ・COASTER SCHOOL BUS
・IPSUM ・HIACE FREEZER
・Wheelchair-customized Vehicle
・PRIUS ・Transport of People with Reduced Mobility
・Wheelchair-customized vehicle(Ramp-
type）
・Vehicle with lift seat for rear passenger
・Vehicle with lift seat for front passenger
・Automatic Rotating and Sliding Passenger
・LAND CRUISER 200 Seat
・LEXUS LX570
・Barrier free device
・LAND CRUISER 70 PICKUP
・LAND CRUISER 70 HARDTOP
・Electric Vehicle Everyday
・Urtra Small Electric Vehicle COMS
・HIACE
・REGIUSACE
・HIACE (for Europe)
・COASTER
1/31
Door slam simulation for durability

analysis with Multibody Dynamics
Contents
1. Doors of car
2. Background and Objective
3. Door slam simulation
3-1. Simulation flow
3-2. Simulation conditions
3-3. Results validation
3-4. Accuracy improvement
4. Future plan –Application to other door types and durability evaluation
5. Conclusion
2/31

Contents
1. Doors of car
5. Conclusion
3/31
Doors of car
Hood Side door Hatch
Doors should fulfill the required functions fully in

door open-close operations during whole car life.
Sliding door Tail Gate Trunk
4/31

Contents
1. Doors of car
5. Conclusion
5/31
Door open-close durability evaluation –conventional approach
Issues •Need the test of original vehicle  Much cost and time
•Unable to change design for different input condition  Need re-test !
Test CAE
Open-close durability Proposal of design
with prototype Static analysis
modification
- Input
(Lock, Cushion rubber)
- Crack information
Unable to evaluate by CAE

without information from test
6/31
Objective
•Complete evaluation by CAE without real product Reduction of number of test reduces
•Able to respond to design modifications design cost and development period
Design CAE Dynamic analysis

Geometry & Property
Door behavior simulation
⇒
Load time history
Structure modification
Stress analysis In-house
Life evaluation system
Close-open durability test

Test
7/31

Contents
1. Doors of car
5. Conclusion
8/31
Study of Door behavior simulation

Estimate the load acting on door during door closing
Consider the non-linearity of displacement-load characteristics of
lock, seal and rubber
Consider the lap clearance on sealing parts and rubbers
Car body is assumed as rigid
Consider the door flexibility
 Study the simulation on the front door as initial step

Clear the locations and requirements for design modification
 Apply to other types of door
9/31

Contents
1. Doors of car
5. Conclusion
10/31
Flow of door slam simulation

Build MBD model
CAD data Define simulation conditions
Analysis
FEM model creation MotionSolve
MotionView
HyperMesh
Modal properties **.mrf (Plot) **.h3d (Animation)
Load time history Deformation
Radioss/Analysis
**.h3d (Flexible body) HyperGraph HyperView
11/31

Contents
1. Doors of car
5. Conclusion
12/31
Model conditions
Whether-strip load
property
Assembly flexible body
Lock position
Close velocity definition
Lock load property Load
Revolute
joints Cushion rubber load
property Displacement
Load property
Load = Stiffness + Damping
Load locations
F = Kx + Cv Weather-strip
Load Cushion rubber
F= disp + Damping coefficient * velocity Lock
13/31

Contents
1. Doors of car
5. Conclusion
14/31
Simulation results
Deformation（Scale 30） Load time history
15/31
Measuring positions
Original model validation Acceleration at door lock
Load at door lock
Acceleration
at door lock Test
Original
Load at upper rubber
acceleration
Load at lower rubber
smaller level after initial peak

Load at door lock
time
 larger lock damping
Test
Original Load at upper rubber
Test
load
Original
Test
Original
load
load
time
time
Need to tune the damping of lock
larger load at first & second peaks
and cushion rubber respectively time
 smaller cushion rubber damping

16/31

Contents
1. Doors of car
5. Conclusion
17/31
Flow of model accuracy improvement

Geometry Input data
HyperMesh Analysis
MotionSolve System Identification
Radioss / Analysis
**.h3d (Flexible Body) HyperStudy

HyperGraph
Build MBD model

Define simulation conditions
Comparison with No
test results
Yes
MotionView End
18/31
Damping optimization (HyperStudy)

{parameter(Lock,"CL", 1,10, 100)}
{parameter(Srubber,"CS", 2, 20, 200)} < Design variables >
{parameter(WStrip,"CW", 1, 10, 100)}
<Force_Vector_OneBody
id = "30101"
type = "ForceOnly"
marker_id = "30102021" Lock
ref_marker_id = "30101010"
fx_expression = "0"
fy_expression = "VARVAL(30100100)+{Lock, %8.5f}*VY(30101280,30102020)"
fz_expression = "0"
/>
id = "30103"
type = "ForceOnly"
marker_id = "30102051"
ref_marker_id = "30101010" Stopper rubber
fx_expression = "0"
fy_expression = "VARVAL(30100300)+{Srubber, %8.5f}*VY(30101310,30102050)"
fz_expression = "0"
/>
id = "30105"
type = "ForceOnly"
marker_id = "30102071"
ref_marker_id = "30101010" Weather strip
fx_expression = "0"
fy_expression = "VARVAL(30100500)+{WStrip, %8.5f}*VY(30101330,30102070)"
fz_expression = "0"
/>
19/31
Damping optimization (HyperStudy)
< Objective >
Minimize SQRT( a2 + b2 + c2 + d2 )
sqrt((max({v_1})-f0)^2+(min({v_1})+f1)^2+(max({v_2})-f2)^2+(max({v_3})-f3)^2)
Load at door lock v_1 Load at upper rubber v_2 Load at lower rubber v_3
a
f0
Load
Time d
c f3
f2
Time Time
f1
20/31
Measuring positions
Modified model validation
Load at door lock Acceleration at door lock
Acceleration
at door lock Test
Original
Modify
acceleration
Load at door lock

Similar to test results time
Test
Original Load at lower rubber
Modify
Test
Original
Modify test
Original
load
Modify
load
load
time
time
time
21/31
Validation of identified damping

Load at door lock Load at upper rubber Load at lower rubber
Te st T est t est
Se dan A Sedan A S edan A
Sedan A
load
load
load
t im e time tim e
Test
T e at Te st
M in i Van B
M in i V an B M in i V an B
load
load
laod
Mini Van B
tim e tim e tim e
Te s t
Te st Te st
SU V C
S UV C SU V C
Load
Load
Load
SUV C
Time Time
Tim e
Confirmed the good correlation in the front doors of

other car types using identified damping.
May need to identify the damping factors for the front doors with much different
structure and mechanism.
22/31

Contents
1. Doors of car
5. Conclusion
23/31
Other type of door application [Hatch]

Weather-strip Revolute joints
load
Define flexible
door
Damper load
Cushion rubber Cushion rubber load

load
Load property
Lock load Condition the closing speed
Load
Load locations
Load = Stiffness + Damping Weather-strip
F = Kx + Cv Cushion rubber
Load
Displacement
Lock
F= + Damp. coef.* velo
disp Damper
24/31
Simulation results on hatch
25/31
Other type of door application [Sliding door]

Cushion rubber
load
Weather-strip load
Flexible door
Flexible car body
Lock load
Condition the
closing speed
Lock load
Rail : point-curve constraint Cushion rubber load
Load = Stiffness + Damping Load locations

F = Kx + Cv Weather-strip
Load Cushion rubber
F= disp
+ Damp. coef.* velo Lock
26/31
Simulation results on sliding door
27/31
Future plan –Durability evaluation
Geometry
MotionSolve HyperStudy
HyperMesh Eigen vectors

Modal composite
Radioss / Analysis
Fatigue analysis
**.h3d (Flexible body) In-house tool or FEMFAT
MotionView
(Build MBD model)
strain
time
Validation of stress time history
28/31

Contents
1. Doors of car
5. Conclusion
29/31
Conclusion
 Developed the process of front door slam simulation in HyperWorks
 Established the Multibody Dynamics technology for door slam
simulation
 Identified the damping factors in comparing with the test results
 Confirmed the ability to simulate the door slam test in HyperWorks
Future plans
 Apply this technology to other types of door
 Door durability evaluation
Using the developed process for product design from now
30/31
Thank you for your attention!
31/31

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2nd European HyperWorks Technology Conference Strasbourg September 30th –October 1st, 2008

Door slam simulation for durability analysis with

○ Takeshi Inoue Hiroaki Hoshino

September 30th –October 1st .2008

Company Profile TOYOTA AUTO BODY CO.,LTD.

Toyota Auto Body is developing and

Door slam simulation for durability

Door slam simulation for durability

Doors should fulfill the required functions fully in

Sliding door Tail Gate Trunk

Door slam simulation for durability

Door open-close durability evaluation –conventional approach

Unable to evaluate by CAE

Design CAE Dynamic analysis

Close-open durability test

Door slam simulation for durability

Study of Door behavior simulation

 Study the simulation on the front door as initial step

 Apply to other types of door

Door slam simulation for durability

Flow of door slam simulation

Modal properties **.mrf (Plot) **.h3d (Animation)

Load time history Deformation

**.h3d (Flexible body) HyperGraph HyperView

Door slam simulation for durability

Assembly flexible body

Door slam simulation for durability

Load at upper rubber

smaller level after initial peak

 smaller cushion rubber damping

Door slam simulation for durability

Flow of model accuracy improvement

**.h3d (Flexible Body) HyperStudy

Build MBD model

Damping optimization (HyperStudy)

Damping optimization (HyperStudy)

< Objective >

Load at upper rubber

Load at door lock

Validation of identified damping

tim e tim e tim e

Confirmed the good correlation in the front doors of

Door slam simulation for durability

Other type of door application [Hatch]

Cushion rubber Cushion rubber load

Simulation results on hatch

Other type of door application [Sliding door]

Load = Stiffness + Damping Load locations

Simulation results on sliding door

Future plan –Durability evaluation

HyperMesh Eigen vectors

**.h3d (Flexible body) In-house tool or FEMFAT

Validation of stress time history

Door slam simulation for durability

Using the developed process for product design from now

Thank you for your attention!

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Modal properties .mrf (Plot) .h3d (Animation)