Simulation Simulation –– Driven Auto Driven Auto ... · Steering & Drive Steering column • Power steering pump • Intermediate shaft ... Shipping test -Three test types : Vessel,

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Simulation Simulation –– Driven Auto Driven Auto Component Development Component Development p pp p

@ @ KdacKdac

* 김 대업

* Korea Delphi Automotive System Corp.

Agenda

1 Kdac Overview

2 CAE Coverage (Functionality & Product)

3 Case Study (Drum Brake)

4 VPD Vision @ Kdac

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Year 1984 : Company establishedYear 2013

- 9 Manufacturing plants in 4 countries (Korea, China, Thailand, India), about 2000 employees- 5 Manufacturing plants & 2 tech center in Korea

KdacKdac OverviewOverview

KdacKdac OverviewOverview

Main products

Electric & Electronics• Alternator

Thermal• HVAC controllerAlternator

• Ignition coil• EGR valve• ECM

HVAC controller• HVAC module• Cooling fan• Radiator• Charge air cooler• Condenser• Compressor

Brake• Caliper brake• Proportioning valve• Power brake• Drum brake• Parking brake

Steering & Drive• Steering column• Power steering pump• Intermediate shaft• Steering gear• Halfshaft• Parking brake • Halfshaft• Intermediate drive shaft

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CAE Coverage CAE Coverage -- FunctionalityFunctionality

Stiffness / Strength

Durability / Fatigue

NVH

ImpactOptimization

Manufacturing

CFD

Original Design Optimized Design

CFD

Available S/W @ Available S/W @ KdacKdac

STAR-CCM+

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CAE Coverage CAE Coverage -- ProductProduct

Steering Column

Power Steering Pump

Intermediate Shaft

Steering Gear

Steering Column / Halfshaft

Steering Column(Impact & Natural Frequency)

Halfshaft

Steering gear : squeak noise (Contact pressure analysis)

Torque Variation Analysis

Brake System


Parking Brake

Power Brake

Proportioning Valve

Caliper Brake

Caliper Brake

Drum Brake

Squeal Noise Analysis (Complex Eigenvalue)

Contact Pressure Distribution

BTV (Brake Torque Variation)

(Pad)

Strength Analysis of Drum Brake Back Plate

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HVAC / PTC


ModelFlow Rate

(CMH)Torque(N-mm)

OASPL(dB)

7 Blades 2721 38.7 56.89 Blades 2670 37.7 57.2

Mold Flow Analysis

Modified

Original Reaction Force at Mounting of Compressor

Structural Integrity of Shroud

Powertrain / Alternator


EGR : Random vibration fatigue

Original

Calculated MeasuredOriginal 99.6 96.5

Mod. Final 97.5 94.0

Final

Mod. Original

Dynamic Stiffness of Ignition coil

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Strength & Fatigue analysis

FE model Strength analysis

Case StudyCase Study

Dynamic analysis

Load history & fatigue material property

Fatigue analysis

Shipping test - Three test types : Vessel, Railcar, Haulaway - Generally haulaway test would be the severest out of three shipping condition- Wheel strap restraint shipping method creates a braking condition during haulaway test.

and parking brake is engaged


The intensity of the braking caused by haulaway test was bigger than general braking load.

Fatigue crack

Haulaway shipping test Haulaway shipping test results

Fatigue crack

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Model Max. Strain[%]

Haulawaytest results

Legacy A 0.86 Pass

Legacy B 0 52 Pass

Analysis results - Internal target of haulaway test was set to specific Max. plastic strain

0.73 % 4.54 %


Legacy B 0.52 Pass

Legacy C 0.73 Pass

Legacy D 0.72 Pass

Legacy E 0.58 Pass

Legacy F 0.54 Pass

G 4.54 Not pass

Design proposal

Legacy C model G model

0.92 %

- Modified G

Model Max. Strain[%]

Haulawaytest results

Modified G 0.92 Pass

Modified G model

Purpose : DFSS is used to identify influential design factors in terms of strength.Initial model : Modified G Parameter Diagram

- Response : Static response, Smaller-the-Better- Orthogonal array : L18

Level


Control factor

Max. plastic strain

Control factorLevel

1 2 3

a Distance 100 150 -----

b Thickness 100 108 120

c Distance 100 108 115

d Distance 100 142 183

e Distance 100 110 119

f Distance 100 111 123

g Height 100 122 143

h Radius 100 150 200

Output responseSystem

Noise factorNoise factor

Noise 1 Durability test load A

Noise 2 Durability test load B

Noise 3 Durability test load C

Unit : Percentage – Level 2,3 to Level 1 ratio

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S/N ratio

Level a b c d e f g h

1 1.33 2.02 1.42 1.38 1.52 1.09 1.34 1.61

2 1.36 1.29 1.36 1.27 1.32 1.51 1.46 1.29

3 ----- 0.73 1.26 1.39 1.21 1.44 1.24 1.14

Level a b c d e f g h

1 -3.10 -7.39 -3.39 -2.46 -4.54 -0.62 -3.27 -4.70

2 -2.82 -3.36 -2.44 -2.99 -3.17 -4.16 -3.11 -2.56

3 ----- 1.87 -3.05 -3.44 -1.17 -4.10 -2.51 -1.61

Mean


Configuration of optimal design 1 (OPT 1)- Maximize the S/N ratio so that variation is minimized- Minimize the mean value

a b c d e f g h

OPT 1 2 3 2 1 3 1 3 3


Model S/N ratio Mean

Initial (=Modified G) 2.4 0.65

OPT 1 12.3 0.20

Gain + 9.9 - 0.45

Initial model OPT 1 model Mean : 0.20

Strength analysis with optimal design 1 (OPT 1)- As shown in the below table,

OPT1 model seems to be more robust than the initial model with 5 % mass reduction

Mean : 0.65 Mean : 0.20

0.29 0.92

5 % Mass reduction

Mean : 0.65

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Methods continuously improving, butCAE Role ?

VPD VisionVPD Vision

Productivity Gain


Key Words of Future State of Key Words of Future State of KdacKdac CAECAE

Up-Front CAE

Simulation Driven

Development

Up Front CAE

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SimulationProcessData


Path to Future State of Path to Future State of KdacKdac CAECAE

Task Automation

Management

Standardization

Best Practice


Auto-generate instability chart Import results of chosen case by user

Define FE model file & Analysis ConditionsAuto-generate case#.inp file by user-defined parameter matrix

Display mode shapeCapture image and animation

Documents

Simulation Simulation –– Driven Auto Driven Auto ... · Steering & Drive Steering column • Power steering pump • Intermediate shaft ... Shipping test -Three test types : Vessel,