Application of a Novel Metal Folding Technology for Automotive BiW Design - Clemson University
-
Upload
altairhtcus -
Category
Technology
-
view
522 -
download
9
description
Transcript of Application of a Novel Metal Folding Technology for Automotive BiW Design - Clemson University
33Application of a Novel Metal
Folding Technology for Automotive
BiW Design
Prathamesh Marathe
1
Prathamesh Marathe
June 5, 2012 CUICAR | Deep Orange 3
33
CU-ICAR (Clemson University International Center for Automotive Research)
• Advanced-technology research campus in collaboration with academia, industry and
government organizations
• The first and only US Automotive Engineering program so far; Master & PhD program
• State-of-the-art equipment & facilities
• Technology neighborhood
2CUICAR | Deep Orange 3 June 5, 2012
33
What is Deep Orange• Vehicle prototype program at CU-ICAR that immerses graduate automotive
engineering students into the world of a future OEM and/or supplier
• Helps students to gain hands on experience
– Students are involved from inception to completion in all phases
– Students get to interact with cross functional faculty members
• Students learn about state of the art technologies and how to integrate these
3CUICAR | Deep Orange 3
• Students learn about state of the art technologies and how to integrate these
Deep Orange 3 Spring – Summer ’12 teamDeep Orange 1 car
June 5, 2012
33
Deep Orange: A New Teaching Paradigm
System DesignDay 193
Market AnalysesStart: Day 1
Product/Production Architectures
Annual new Prototype Vehicle releases
from two-year Development Cycles
4
ValidationEnd: Day 712
System IntegrationDay 523
Concept
Selection
Target Validation
Graduation
Manufacturing/Assembly
An integral feature of our
MS/PhD Research & Education Program
June 5, 2012 CUICAR | Deep Orange 3
33
The Importance of Industry Participation
• Provide realistic problem statements and challenges that address current
and future (industry) issues.
• Give access to new innovations, materials, technologies and processes.
• Mentor students during regularly scheduled meetings.
5
• Mentor students during regularly scheduled meetings.
• Provide crucial background information on subject matter often not
accessible in an academic setting.
• Fund the overall program.
June 5, 2012 CUICAR | Deep Orange 3
33
The Deep Orange 3 Project
• Joint Sponsorship of
– Mazda North American Operations (MNAO)
– Clemson University-International Center for Automotive Research (CU-
ICAR)
– Arts Center College of Design (ACCD)
• Designed to give large scale view of the automobile design and engineering
6
• Designed to give large scale view of the automobile design and engineering
process
– Marketing Data
– Design and Engineering
– Validation and Testing
CUICAR | Deep Orange 3 June 5, 2012
33
IOI Technology
• Conventional Technology: Stamping of sheets
• Drawbacks
– High tooling cost
– Complicated process
Source: http://www.industrialorigami.com/solutions/transportation.cfm
7
• New Technology: Folding of sheets into simple shapes
• Advantages
– Low cost tooling
– Unskilled labor force can be easily trained (Less complicated)
– Lesser time requirement
– Lower Number of parts
– Accurate laser cut holes for mounting components and riveting
CUICAR | Deep Orange 3 June 5, 2012
Source: http://www.industrialorigami.com/solutions/transportation.cfm
33
Application of IOI Technology
• Topology of vehicle
• Packaging of other assemblies
• Chassis
• Powertrain
• Occupants
• Analysis of structure for torsion and bending stiffness
8
• Analysis of structure for torsion and bending stiffness
• Analysis of structure for dynamic loading
CUICAR | Deep Orange 3 June 5, 2012
33
Application of IOI Technology
9CUICAR | Deep Orange 3 June 5, 2012
33
Components of BiW
Front Crash
Structure
Floor And
SpaceframeRear Crash
Structure
10CUICAR | Deep Orange 3 June 5, 2012
33
FEA of IOI Structure
• Use of Hypermesh to generate mesh
– Sheet metal parts and Space frame pipes as 2D shell mesh
– Thicker geometries as 3D tetra mesh
11CUICAR | Deep Orange 3 June 5, 2012
2D Shell Mesh in Floor Assembly
3D Tetra Mesh in
Spaceframe Assembly
33
FEA of IOI Structure
• Adhesives used to connect different sheets
• Spot weld connectors used to connect space frame to IOI structure
• Boundary conditions and loads
– For Torsional Stiffness of the BiW
• Loads applied at front strut towers
• Constraints at front and rear with beams to simulate real life situations
12
• Constraints at front and rear with beams to simulate real life situations
CUICAR | Deep Orange 3 June 5, 2012
33
FEA of IOI Structure (Contour Plots)
• Use of Hyperview to do post processing of analysis results
– Displacements
– Induced stresses
13CUICAR | Deep Orange 3 June 5, 2012
33
FEA of IOI Structure (Twist Angle Vs Vehicle Length)
14CUICAR | Deep Orange 3 June 5, 2012
33
Future Steps
• Carryout Dynamic Loading of the structure
• Test the fold ability of the sheets
• Realize the BiW structure form sheets and spaceframe.
15CUICAR | Deep Orange 3 June 5, 2012
33
Acknowledgements
• Thanks to Dr Paul Venhovens for support and supervision
• Thanks to DO-3 team for timely help
• Thanks to Altair and Dr David Schmueser for this opportunity to present the
work at this conference
16CUICAR | Deep Orange 3 June 5, 2012
33
Thank You
17
Thank You
June 5, 2012 CUICAR | Deep Orange 3