Design Robustness & Process Capability By Simufact & · PDF fileDesign Robustness & Process...
Transcript of Design Robustness & Process Capability By Simufact & · PDF fileDesign Robustness & Process...
Schaeffler Group Automotive
Simufact 12th Round Table Conference Bamberg, Germany
Design Robustness & Process CapabilityBy
Simufact & 6 SigmaDr. Kunding Wang/Principal FEA Analyst
Luk USA LLCWooster, Ohio, USA
September 28, 2010 12th Simufact Round Table Conference Page 2
Product Range Automotive
Variablevalve timing
Finger follower with hydr. pivot element
Hydraulic tappet
Drawn needle bearing
Overrunningalternator pulley
Timing chain drive
Strut bearing
Shifting system
• Engine and Trans-mission Components
Clutch release system CVT componentsDual mass
flywheel
SAC
• Components for Clutch and transmission systems
Torque converterSensor-wheel bering
Tapered roller brg.Tandem angular
contact ball bearing
Deep grooved ball bearing
• Wheel- Modules• Transmission brg. Dual clutch system
dry/wet
Balance shaftwith reduced mass
Toothed chain fortiming drives
Ball screw drive
September 28, 2010 12th Simufact Round Table Conference Page 3
1. Simufact as simulation tool for
• Manufacturing process.
• Performance evaluation.
• Durability life assessment.
• Robustness and capability prediction.
2. Summary.
3. Q & A.
Outline
September 28, 2010 12th Simufact Round Table Conference Page 4
Automotive Torque Converter
September 28, 2010 12th Simufact Round Table Conference Page 5
Integrated Product Development
September 28, 2010 12th Simufact Round Table Conference Page 6
Started Simufact.forming
Added Simufact.forming GP
Forming
+ Riveting
+ Tooling
+ Welding
+ Heat Treatment
Rapid Process Optimization Demand Growth
September 28, 2010 12th Simufact Round Table Conference Page 7
Total Simulations
Heat Treatment
Welding
Riveting
Tooling
FormingTypes
Process Simulations
Simufact.forming
Simufact.forming
Simufact.forming
Simufact.forming
Simufact.formingSoftwares
CAE Specialists
Tool Designers
Users
CAE Specialists
Users
Non-Simufact
Non-Simufact
Non-SimufactSoftwares
Product robustness prediction
Product durability assessment
Product function evaluation
TypesPerformance Simulations
Simulation Classification
• Take the model, and use it for further process optimization. • Take the solution (t16), and use it for performance
simulations
CAE Specialists
Simufact
Simufact
Simufact
September 28, 2010 12th Simufact Round Table Conference Page 8
Objective:• Stamp flange from coil steel instead of machined forging.
Benefits:• Reduce overall cost • More value added in-house
Simufact Flange Forming Optimization
September 28, 2010 12th Simufact Round Table Conference Page 9
Objective:• Stamp stator instead of die cast aluminum
Benefits:• Cost reduction potential• Performance improvement potential
Simufact Stamp Stator Optimization
September 28, 2010 12th Simufact Round Table Conference Page 10
Objective:• Design and process optimization
Benefits:• Reduce develop time • Reduce prototypes• Reduce developmental tests• Drive inventive design and process
Simufact Blind Riveting Simulation
Piston
Cover
Riveting Die
Punch
Rivet
September 28, 2010 12th Simufact Round Table Conference Page 11
Objective:• Eliminate quenching cracks• Avoid excessive quenching distortion
Benefits:• Reduced scraps
Simufact optimized process to eliminate quenching cracks
Quenching crack
Simufact optimized process reduced quenching distortion
Simufact Quenching Process Optimization
September 28, 2010 12th Simufact Round Table Conference Page 12
Forming Simulation
Overbend stress analysis
Pressure cycling stress analysis
Goodman Analysis
S-N Curve
sfFo
rmin
gGP
σ ε Geo
σ ε
σ ε
Δσ
Cycles
Ove
rben
d Fo
rce
Simufact Durability Life Assessment Methodology
Overbend Piston
September 28, 2010 12th Simufact Round Table Conference Page 13
Overbend by forming
Pressure Cycling
Permanent Set
Forming
Overbend Pressure cycling
Durability Assessment
Overbend Piston Durability Assessment
September 28, 2010 12th Simufact Round Table Conference Page 14
Quenching - Forming
Tempering
Shot peening
Testing
Sim
ufac
tDiaphragm Spring Performance Evaluation
September 28, 2010 12th Simufact Round Table Conference Page 15
F
x
2nd Stroke
Testing
1st Stroke
Simufact Performance Evaluation
September 28, 2010 12th Simufact Round Table Conference Page 16
Multiple patents
Original Design
Simufact Drives Inventive Process Design
No damage
Some damages
September 28, 2010 12th Simufact Round Table Conference Page 17
Front coverHub
Back plateDrive ring
ωPDynamic
Bolted to the dyno thru. the flex plate
Simufact MIG Weld Joint Durability Assessment
September 28, 2010 12th Simufact Round Table Conference Page 18
Functions:
• Join the piston and the drive ring
• Transmitting torque
Requirements:
• Durable pressure cycling• Avoid automatic transmission fluid leakage
TCC Piston plate rivet joint design
September 28, 2010 12th Simufact Round Table Conference Page 19
1. Concurrent Simulation
4. Pre-Screening Feasible Solutions 3. Robustness & Capability
2. FEA DOE Optimization
Apply Pressure
Simufact 6σ Rivet Joint Robustness
September 28, 2010 12th Simufact Round Table Conference Page 20
Piston plate Carbon steel HR
Friction paper
Rigid punch
Rigid stripper
Case Hardened Strain limit: < 2%
Rivet Carbon steel
Simufact Rivet Joint Modeling
September 28, 2010 12th Simufact Round Table Conference Page 21
Control OutputCritical Factors
6 σ Rivet Joint DOE Table
September 28, 2010 12th Simufact Round Table Conference Page 22
Rivet Joint Robustness & Process Capability
September 28, 2010 12th Simufact Round Table Conference Page 23
> Requirement20%25%3FEA DOE80%75%9Avoidance
12Prototypes
Ø RequirementDesign RobustnessBudget %Lead Time %
100%100%DOE
Pre-
scre
en F
easi
ble
Solu
tions
Benefits
Benefits
September 28, 2010 12th Simufact Round Table Conference Page 24
1. Simufact based performance simulation is successfully developed.2. Process simulation is integrated with product development.3. Sophisticated technology is used by tool designer.4. Simufact simulation biomes a strategic tool in product development.5. Simufact based process and performance simulations.q improves accuracy, efficiency, and confidence.q reduces developmental tests.q shortens development cycles.q reduces production cost.q increases knowledge retention.q drives inventive design and process.
• multiple patents• trade secrets
Summary