1. Vehicle Durability Workshop – 2012 Americas HTC
Multi-Body Dynamics Team, Altair
Innovation Intelligence®

2. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Agenda - Vehicle Durability Workshop
Start Time Topic
3.15
3 15 PM Introduction
3.25 PM HyperWorks for Vehicle Durability
3.50 PM MotionView for Durability Modeling
4.15 PM MotionSolve
4.30 PM CD-Tire Introduction
4.45 PM Flexbodies
5.00 PM Customer – Altair Development Interaction
p
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3. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Don’t Miss! - MBD Customer Breakout Session
• When?
• Thursday May 17th 2012 – 1 15 to 2 45 PM EST
Thursday, 1.15 2.45
• Who?
• Honda
H d R&D
• Presenter: Hernan Mercado-Corujo
• Full-Vehicle Multi-body Simulations on Virtual Roads - The Challenges of Success
• Fraunhofer
• Presenter: Axel Gallrein
• CDTire: State-of-the-Art Tire Models For Full Vehicle Simulation
• Altair
• Multi-Physics
Multi Physics with MotionSolve
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4. HyperWorks for Vehicle Durability
Innovation Intelligence®

5. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Presentation Outline
• Brief Introduction to Durability
• How are customers using HyperWorks for Durability?
• What are the key elements to assess durability?
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6. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
What is Durability?
• Ability to withstand to fatigue, corrosion, wear, creep, ...
• P d i
Predominant failure mode is fatigue
t f il d i f ti
• Fatigue is failure due to repeated cyclic load, well below the failure
strength of the material
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7. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Physics of Fatigue
(Crack formation)
(Crack propagation)
• Caused by cyclic plastic deformation in a localized area.
• P
Presence of a small crack
f ll k
• Pre-existing defect on the surface of a component
• Not possible to model using traditional FE
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8. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Causes of Varying Loads
Sources of Varying Loads on Structures
Road Profile Closures Wind Turbine etc..
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9. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Which Areas Of The Vehicle Are Of Interest?
Passenger Cars Light Trucks Heavy Trucks Buses Earth-Moving Rail
Agricultural General Utility Military Vehicles Snowmobiles Motorcycles
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10. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Presentation Outline
• Brief Introduction to Durability
• How are customers using HyperWorks for Durability?
• What are the key elements to assess durability?
10

11. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Application: Fatigue validation of motorcycle frame
• Customer: Piaggio, Italy
• Objective:
• Establish a virtual simulation process for
motorcycle frame
• Solution:
• Roller test bench dynamic simulation using Multi-
Multi
Body Dynamics (MotionView / MotionSolve)
• High fidelity FTire tire model
• Accurate load histories = Accurate life prediction!
• Benefits:
• Exceptional correlation between simulation
(MotionSolve) and test data
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12. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Application: Radiator test bench study
• Customer: Modine, USA
• Objective:
• Perform multi-axes table simulation using Multi-body
Dynamics
• The shaker table s bjected to a s ept sine motion
subjected swept
• Solution:
• Flexible Multi-body simulation using MotionView /
MotionSolve
• Accurate flexbody generation using Radioss
• Benefits:
• Exceptional correlation between simulation
(MotionSolve) and test data
• Robust flexbody solution
• Seamless durability process within HyperWorks
12

13. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Application: Durability evaluation of a washer
• Customer: MABE, Mexico
• Objective:
• Accurately study the behavior of the hydraulic
balance ring of a washing machine
• Extract
E tract forces on the suspension rods for fatigue
s spension fatig e
evaluation
• Solution:
• A Multi-body model of the flexible rotor and stator in
MotionView
• A detailed balance ring crescent mechanism as a
sub-system simulated in MotionSolve
y
• Benefits:
• MotionSolve (simulation) force histories match well
with that of the force transducers (test)
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14. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Application: Automotive closures durability
• Customer: Toyota, Japan
• Objective:
• Complete evaluation of closures using CAE
• Component load generation using MBD
• Reduce no of physical tests
no.
• Solution:
• MotionView to model the closure systems
• Model non-linearity of lock, seal and rubber
non linearity lock
• Consider lap clearance on sealing parts and rubbers
• MotionSolve for accurate Multi-body simulations
• Benefits:
• Excellent correlation between MotionSolve and test
• A virtual process for door slam evaluation was
established using HyperWorks
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15. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
And More…
• Honda Reliability Group
• Thursday May 17th 2012 – 1 15 to 2 45 PM EST
Thursday, 1.15 2.45
• Altair Bus Durability Project
• Thursday, May 17th 2012 – 8.30 to 10.00 AM EST
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16. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Presentation Outline
• Brief Introduction to Durability
• How are customers using HyperWorks for Durability?
• What are the key elements to assess durability?
16

17. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
The Key Elements of Durability Evaluation
Real World Usage
Representative Duty Cycle
Component Loading Histories
Fatigue Assessment
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18. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
The Key Elements of Fatigue Life Estimation
FE Model
Geometry
Fatigue S/N E/N Estimated
Material Data Analysis life
Component
Load
L d
Spectrum
Load spectrum MBD model
Road data acquisition
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19. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
HyperWorks for Durability
• HyperWorks has comprehensive durability capabilities:
• HyperGraph  Duty cycle visualization (eg: Rainflow counting)
counting)…
• MotionView  Vehicle Library, Load Export,…
• MotionSolve  Component load generation, quasi-static and transient analyses..
• Tire models  FTire CD-Tire, RMODK, MF-SWIFT
FTire, CD-Tire RMODK MF-SWIFT,..
• Radioss  CMS (flexbodies), unit load analysis, linear static
• HyperView  Hot spot visualization..
• OptiStruct, HyperStudy,….
• HWPA  FEMFAT, DesignLife,..
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20. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Templates to Meet Specific Needs
DUTY MBD FATIGUE POST
DUTY Measured MBD Component FATIGUE
Loads Loading POST
CYCLE ANALYSIS ANALYSIS
Load Component
Locations & Stress State
Orientations FEA
FE
ANALYSIS
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21. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Templates to Meet Specific Needs
ROAD
ROAD
MODEL
MBD FATIGUE POST
Road + Driver MBD Component FATIGUE
POST
Inputs ANALYSIS Loading ANALYSIS
DRIVER Load
Component
MODEL Locations &
FE Stress State
Orientations
O i t ti
DRIVER FE
ANALYSIS
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22. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Templates to Meet Specific Needs
DUTY FE FATIGUE POST
DUTY Measured Loads
FEA FATIGUE POST
CYCLE Loads Stress State
MBD FATIGUE POST
Event Component
MBD FATIGUE POST
Definition Loading
FE
Load
Locations & Component
Orientations Stress State
FEA
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23. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Summary
• Altair offers a comprehensive solution for Vehicle Durability
Task Tool
Component modeling  HyperMesh
Flex body creation  Radioss
System modeling  MotionView
Road & Tire Modeling  FTire, CDTire, RMOD-K , MF-SWIFT
Loads generation  MotionSolve
Fatigue calculation  HWPA (FEMFAT, Design Life)
Visualization  HyperView/HyperGraph
Optimization  OptiStruct, HyperStudy
Putting it all together  Durability Director (ESG)
• The solution is industry validated.
validated
• The solution is available to all HyperWorks customers
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24. MotionView for Durability Modeling
Innovation Intelligence®

25. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Durability Analysis – Possible Approaches
• Static loads:
• Model a representative vehicle in MotionView
p
• Setup a quasi-static load template
• Run (quasi-)static analysis in MotionSolve
• Extract loads (body forces) from MotionSolve to RADIOSS
• Run inertia li f
R i ti relief analysis (INREL -2) i RADIOSS
l i 2) in
• ….
• Semi-analytical durability:
• Model a representative vehicle in MotionView
• Model a virtual test rig (eg: 4-poster) and input:
• Forces directly at spindle – need to control drift (or)
• Acceleration at spindle – need to convert acceleration to displacement (or)
• Back calculated displacement at tire – need to use Remote Parametric Control
p
• Run transient simulation in MotionSolve
• Extract component loads (and accelerations) from MotionSolve
• Unit load analysis in Radioss to extract stress states
• ….
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26. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Durability Analysis – Possible Approaches
• Fully analytical durability:
• Model a representative vehicle in MotionView
• Model a virtual tire and a digitized rough road (virtual proving ground events..)
• Setup a driver (controller)
• Run transient simulation in MotionSolve
• Extract component loads (and accelerations) from MotionSolve
• Unit load analysis in Radioss to extract stress states, etc
• ….
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27. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
How do you assure model fidelity?
• Before starting your durability runs, make sure that:
1.
1 You obtain good K&C correlation in half vehicle models
2. Later assemble the two half’s of the vehicle to build full vehicle
3. Run a static equilibrium analysis to get the CG and tire patch loads right
4.
4 Decide which parts need to be flexible
• Key is to capture the “correct” compliance
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28. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Static Load Analysis
• Definition:
• This is a quasi-static simulation to study the effect of various load cases applied at the wheel
center and tire patch.
• Required input:
• Point of application of the load ( wheel center or tire patch )
• Load direction
• Load type ( force or displacement )
• Load in Newton, Newton-mm or displacement in mm.
• Load multiplier.
• Load case number that the load belongs to.
• Description of task:
D i ti ft k
• To begin with a static simulation is performed with all the active loads belonging to a load
case. This is followed by resetting the set of loads in the load cases and the next set of load
cases is applied. The process is repeated till all load cases are applied.
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29. MotionSolve Overview
Innovation Intelligence®

30. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
What is MotionSolve?
• An Industry proven Multi-Body Solver based on the laws of mechanics
• Widely applicable across many industries and applications
• Deals with overall system behavior where large non-linear motion is the
dominating characteristic
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31. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
What can MotionSolve do for you?
• Supports many types of analyses
• Assembly
• Kinematics
• Statics
• Quasi-statics
• Eigenvalue and State Matrix Generation
• Transient dynamics
• Complex analyses modes can be created by
chaining a sequence of basic analyses
• Capable of multi-disciplinary simulation
involving FE, CFD and Controls
g ,
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32. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Why is MotionSolve special?
• Accurate
• Hundreds of models correlated between
MotionSolve & competition and MotionSolve
& Test
• Comprehensive set of modeling elements
• With unmatched solver customization
• Easy to use
• Support for Python & Matlab user-
subroutines.
subroutines
• No compiler required
• Hard to break
• A robust solver used in a variety of industries
y
• >300 companies use MotionSolve!
• Fast
• Efficient formulation for flexbodies
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33. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Summary
• Altair is uniquely positioned to offer the combination of MBS, FE,
Controls, 1D simulation, Optimization and process based
solutions customer wants
• Altair offers a comprehensive MBS solution platform
• Altair solutions are open and easily customized. Altair is
standardizing on Python
• Altair’s MBS team partners with customers to ensure their
success
• Altair’s solution is available to ALL HyperWorks customers at no
incremental cost, provided adequate tokens exist
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34. Thank You!
Keshav (keshavs@altair.com)
Innovation Intelligence®