Post on 19-Mar-2020
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Agenda- Volvo cars optimization arena
- Wheel suspension cluster
- Individual thesis presentations
- Lessons learned
11/3/2016 VOLVO CARS OPTIMIZATION ARENA HARALD HASSELBLAD 91770 WEIGHT MANAGEMENT AND OPTIMIZATION
Arena
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Pilot run
Purpose
- Network
- Share learnings
- discuss challenges
Volvo cars optimization arena
11/3/2016 VOLVO CARS OPTIMIZATION ARENA HARALD HASSELBLAD 91770 WEIGHT MANAGEMENT AND OPTIMIZATION
Wheel suspension cluster
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Optimization of Wheel Suspension Packaging
Structural Topology and Shape Optimization
Balancing of Wheel Suspension Packaging,
Performance and Weight
11/3/2016 VOLVO CARS OPTIMIZATION ARENA HARALD HASSELBLAD 91770 WEIGHT MANAGEMENT AND OPTIMIZATION
Optimization of Wheel Suspension Packaging
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MSc Thesis Students:
Karl H. Andreasson, chalmers university of technology
Mattias Linder, chalmers university of technology
Supervisors:Daniel Molin, SA Wheel suspension system & strucutres, 94530 wheel
suspension
Dr. Magnus Bengtsson, researcher at the Dpt. Of product & production
development
11/3/2016 OPTIMIZATION OF WHEEL SUSPENSION PACKAGING KARL HANSEN ANDREASSON & MATTIAS LINDER 94530 WHEEL SUSPENSION
Optimization of Wheel Suspension Packaging
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Scope of the workObjective
Find a suitable methodology for efficient data transfer from CAE to CAD software,
which reduces lead time and increases precision during packaging analysis.
Challenges
- How do we minimize information loss in the transfer process?
- How do we develop a methodology which is more efficient, without differing too much from todays working procedure?
- How do we Achieve a high degree of automation without compromising user control?
Limitations
- Focus on Rear wheel suspension
- Use software licences which are currently available at Volvo cars wheel suspension department
11/3/2016 OPTIMIZATION OF WHEEL SUSPENSION PACKAGING KARL HANSEN ANDREASSON & MATTIAS LINDER 94530 WHEEL SUSPENSION
Optimization of Wheel Suspension Packaging
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Striving towards developing an optimized concept for the wheel suspension is
of great importance for future competitiveness, this requires:
- A tight coupling between CAD and CAE
- Weight, cost and lead time reduction through quicker design loops
- Optimized packaging analysis through increased precision
Background
11/3/2016 OPTIMIZATION OF WHEEL SUSPENSION PACKAGING KARL HANSEN ANDREASSON & MATTIAS LINDER 94530 WHEEL SUSPENSION
Optimization of Wheel Suspension Packaging
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Motions transferred through catia application:
- Generate replay file for further analysis
- Map catia v5 instances to motions from adams/car
- Include bushing stiffness
- include all timesteps
Solution- Considerable reduction of lead time
- Increased precision during packaging analysis
- Enables quicker design loops for further packaging optimization
Benefits
11/3/2016 OPTIMIZATION OF WHEEL SUSPENSION PACKAGING KARL HANSEN ANDREASSON & MATTIAS LINDER 94530 WHEEL SUSPENSION
Balancing of Wheel Suspension Packaging,
Performance and Weight
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MSc Thesis Students:
Joakim Skön, chalmers university of technology
Kanishk Bhadani, chalmers university of technology
Supervisors
PH.d. Harald hasseblad, Senior Analysis Engineer, 91770 Weight
management and optimization
Dr. Magnus Bengtsson, researcher at the Dpt. Of product & production
development
11/3/2016 BALANCING OF WHEEL SUSPENSION PACKAGING, PERFORMANCE AND WEIGHT KANISHK BHADANI & JOAKIM SKÖN 91770 WEIGHT MANAGEMENT AND OPTIMIZATION
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Objective
Find a process/methodology and tools to balance packaging conflicts. The purpose is to find the optimal
weight and performance for the rear wheel suspension.
Challenges
- Integrate CAD and CAE engineers work in order to implement optimization in the early stages of wheel
suspension development at Volvo Cars.
- To perform simultaneous design volume optimization on two components of the wheel suspension, which
are competing for packaging space.
Limitations
- The system of interest is the Upper control arm and the Lower control arm of the rear wheel suspension.
- Changes on the components should only affect components within the wheel suspension.
Scope of the work
Balancing of Wheel Suspension Packaging,
Performance and Weight
11/3/2016 BALANCING OF WHEEL SUSPENSION PACKAGING, PERFORMANCE AND WEIGHT KANISHK BHADANI & JOAKIM SKÖN 91770 WEIGHT MANAGEMENT AND OPTIMIZATION
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Balancing of Wheel Suspension Packaging,
Performance and Weight
Design volume
creationDetailed optimization
Initial design space
Design volume
optimization
and validation
Balanced design space
FEM verification
Early concept
development
FEM verificationConcept geometry
Model realization
Proposed process
Current process
11/3/2016 BALANCING OF WHEEL SUSPENSION PACKAGING, PERFORMANCE AND WEIGHT KANISHK BHADANI & JOAKIM SKÖN 91770 WEIGHT MANAGEMENT AND OPTIMIZATION
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Balancing of Wheel Suspension Packaging,
Performance and Weight
11/3/2016 BALANCING OF WHEEL SUSPENSION PACKAGING, PERFORMANCE AND WEIGHT KANISHK BHADANI & JOAKIM SKÖN 91770 WEIGHT MANAGEMENT AND OPTIMIZATION
Structural Topology and Shape Optimization
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MSc Thesis Student:
Robin Larsson, Chalmers university of technology
Supervisors
Iris Blume, CAE engineer, 91510 Endurance Attribute and Chassis CAE
Håkan Johansson, Associate Professor, Division of Dynamics, Dpt. of
Applied Mechanics
11/3/2016 STRUCTURAL TOPOLOGY AND SHAPE OPTIMIZATION ROBIN LARSSON 91510 ENDURANCE ATTRIBUTE AND CHASSIS CAE
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Scope of the work
Objective
Find a suitable methodology for structural topology and shape optimization of a rear lower control arm regarding component development in early
phases of the design process.
Challenges
- What objective function together with suitable constraints?
- What boundary conditions and load cases can be included with respect to the optimization context?
- How to include design constraints from the manufacturing process?
- How to implement topology and shape optimization as a natural part of the design process?
Limitations
- Cast simulation is not included
11/3/2016 STRUCTURAL TOPOLOGY AND SHAPE OPTIMIZATION ROBIN LARSSON 91510 ENDURANCE ATTRIBUTE AND CHASSIS CAE
Methodology for Topology and Shape Optimization
of a rear lower control arm
Methodology for Topology and Shape Optimization
of a rear lower control arm
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Requirements
- Stiffness (Linear FE analysis)
- Strength events (Linear and non-linear FE analysis)
- Fatigue
Name
SPA RLCA with leaf spring
Material
Aluminium
Manufacturing method
Sand casting
Current Component
11/3/2016 STRUCTURAL TOPOLOGY AND SHAPE OPTIMIZATION ROBIN LARSSON 91510 ENDURANCE ATTRIBUTE AND CHASSIS CAE
Methodology for Topology and Shape Optimization
of a rear lower control arm
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Topology optimization
Objective function
Min compliance
Load cases
Stiffness + all strength
Constraints
Volume fraction
Settings
Checkerboard filter = 12mm
11/3/2016 STRUCTURAL TOPOLOGY AND SHAPE OPTIMIZATION ROBIN LARSSON 91510 ENDURANCE ATTRIBUTE AND CHASSIS CAE
Methodology for Topology and Shape Optimization
of a rear lower control arm
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Multi-objective shape optimization
Objective function
Minmax
EPS + damage
Load cases
Worst case EPS + Fatigue
Manufacturing Constraint
Grow control
Hotspots
11/3/2016 STRUCTURAL TOPOLOGY AND SHAPE OPTIMIZATION ROBIN LARSSON 91510 ENDURANCE ATTRIBUTE AND CHASSIS CAE
Structural optimization of
powertrain mounts rubber parts
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MSc Thesis Student:
Jens Medbo, Chalmers university of technology
Supervisors:Daniel Högberg, Structural Analyst, 97481 Powertrain
mounts, Volvo Cars
Prof. Mikael Enelund, dpt. Of Applied Mechanics,
Chalmers university of technology
Optimizing torque rod geometry to meet static stiffness specification
11/3/2016 STRUCTURAL OPTIMIZATION OF POWERTRAIN MOUNTS RUBBER PARTS JENS MEDBO POWERTRAIN MOUNTS 97481
Structural
optimization
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Scope of the work
Structural optimization of
powertrain mounts rubber parts
11/3/2016 STRUCTURAL OPTIMIZATION OF POWERTRAIN MOUNTS RUBBER PARTS JENS MEDBO POWERTRAIN MOUNTS 97481
Objective
develop a method for structural optimization of powertrain mount’s rubber parts,
Which Enables Volvo cars to design a build to print torque rod which will reduce lead times
Challenges
- Modelling rubber materials
- Software integration
- KeEping optimization time low
Limitations
- Focus on Torque rods
- Focus on fine tuning of geometry; shape and size optimization
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Structural optimization of
powertrain mounts rubber partsBackgorund
- Torque rod development today can be very time
consuming with several iterations between Volvo
Cars and supplier to meet specifications
- A method for developing a Build to Print torque
rod is needed to shorten lead times
- Structural optimization of rubber parts is
considered a key activity in realizing a Build to
Print torque rod; optimization method developed
in this master’s thesis project Left Lower Tie-Bar
Right Lower Tie-Bar
Left Hand MountRight Hand Mount
Right Upper Tie-Bar
STRUCTURAL OPTIMIZATION OF POWERTRAIN MOUNTS RUBBER PARTS JENS MEDBO POWERTRAIN MOUNTS 9748111/3/2016
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Structural optimization of
powertrain mounts rubber parts
1. Pre-process in HyperMesh: Mesh, contacts and loadsteps
2. Assign material: predefined or library of different materials
3. Morph geometry, generate shapes and export design variables
4. Set up optimization in HyperStudy. Register Abaqus as solver and parameterize input file
5. Run System Bounds Check to ensure objective stiffness curve lies within design space
6. Perform a DoE to evaluate design variables
7. Run optimization. Objective function: minimize sum of distances to objective stiffness curve
squared
8. Post process: export optimized geometry
Concept torque
rod geometry
Static stiffness
specification
Optimized torque
rod geometry
meeting static
stiffness spec.
Input Torque rod optimization Output
method
11/3/2016 STRUCTURAL OPTIMIZATION OF POWERTRAIN MOUNTS RUBBER PARTS JENS MEDBO POWERTRAIN MOUNTS 97481
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Structural optimization of
powertrain mounts rubber partsResults
11/3/2016 STRUCTURAL OPTIMIZATION OF POWERTRAIN MOUNTS RUBBER PARTS JENS MEDBO POWERTRAIN MOUNTS 97481
Force-displacement plot Nominal and optimized geometry
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Structural optimization of
powertrain mounts rubber partsfuture
Higher level of
automation in
optimization process
Topology optimization?
Input: Design space with boundary
conditions and a stiffness
specification. How should metal and
rubber be distributed to meet spec?
Rapid prototyping of
torque rods to enable
fast verification of
optimized geometries
Include dynamic
stiffness in
optimization Increase knowledge in
modelling and testing
rubber materials
11/3/2016 STRUCTURAL OPTIMIZATION OF POWERTRAIN MOUNTS RUBBER PARTS JENS MEDBO POWERTRAIN MOUNTS 97481
Include Stress and
strain constraints
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MSc Thesis Student:
Adrian Måhlén, Linköping University
Supervisor:
Alexander Govik, Ph.d., 93720 painted body & closures
Bo torstenfelt, associate professor, division of solid mechanics
shape optimization OF THIN SHEET STRUCTURES,
WITH RESPECT TO BUCKLING
SHAPE OPTIMIZING SHEET STRUCTURES WITH RESPECT TO BUCKLING ADRIAN MÅHLÉN 93720 PAINTED BODY & CLOSURES11/3/2016
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Objective
Explore Topography Optimization as a method for increasing the load bearing
capacity of sheet structures with respect to buckling. Suggest an Optimization
process
Challenges
- Reduce weight of vehicles. High Strength Steel → Ultra High Strength Steel
(Boron Steel) in Volvo car bodies
- Thin sheet structures are prone to buckle limiting the load bearing capacity
Limitations
- Manufacturing aspects are not considered
- Topography optimizations are conducted solely in altair optistruct
Body Structure of the Volvo XC90
Scope of the work
shape optimization OF THIN SHEET STRUCTURES,
WITH RESPECT TO BUCKLING
SHAPE OPTIMIZING SHEET STRUCTURES WITH RESPECT TO BUCKLING ADRIAN MÅHLÉN 93720 PAINTED BODY & CLOSURES
11/3/2016 26
- Topography Optimization→ Shape optimization with automatically
generated design variables covering the design space. Optimal reinforcing bead
patterns for thin shell structures are obtained, sheet thickness is kept
constant
- Typical use: Sheet structure designs with stiffness- and/or eigenfrequency
requirements, weight addition is minimal
- User input: topographical shape variable definition, requirement on bead
pattern (linear beads, symmetric w.r.t. to defined planes, radial etc.)
Topographical shape variable Various bead patterns
shape optimization OF THIN SHEET STRUCTURES,
WITH RESPECT TO BUCKLING
Topography Optimization basics
SHAPE OPTIMIZING SHEET STRUCTURES WITH RESPECT TO BUCKLING ADRIAN MÅHLÉN 93720 PAINTED BODY & CLOSURES
11/3/2016 27SHAPE OPTIMIZING SHEET STRUCTURES WITH RESPECT TO BUCKLING ADRIAN MÅHLÉN 93720 PAINTED BODY & CLOSURES
- Optimization of Sill beam
- Objective: Increase load bearing capacity in compression and bending about
Y- and Z-axes. Requirement on constant cross-section (Linear bead patterns)
and weight
+45% comp +26% +Y-bend
+6% -Y-bend
+50% +Z-bend
+47% -Z-bend
Optimized FE-model +2% weight additionSill beam model Original Cross-
section
Optimized Cross-section
Topography Optimization
Nonlinear FE responses
Original vs Optimized Sill Beam Geometry
Sill beam results
shape optimization OF THIN SHEET STRUCTURES,
WITH RESPECT TO BUCKLING
Student Benefits
- Networking
- Forum for discussing common software challenges
- Information sharing
Company Benefits
- Initiation of cross-functional discussions
- Greater value from Theses
- Networking
Improvements
- Initiate workshops for discussing issues
- Define a clear structure for information sharing
- Formulate & communicate clear purpose & goal of
collaborating
Lessons learned
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