Volvo cars optimization arena - Chalmers · 2016-11-30 · 2 Agenda - Volvo cars optimization arena - Wheel suspension cluster - Individual thesis presentations - Lessons learned

Volvo cars optimization arena

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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


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



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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


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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



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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



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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




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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




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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


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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


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




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Topology optimization

Objective function

Min compliance

Load cases

Stiffness + all strength

Constraints

Volume fraction

Settings

Checkerboard filter = 12mm




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Multi-objective shape optimization

Objective function

Minmax

EPS + damage

Load cases

Worst case EPS + Fatigue

Manufacturing Constraint

Grow control

Hotspots


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




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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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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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


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powertrain mounts rubber partsResults


Force-displacement plot Nominal and optimized geometry

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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


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 OPTIMIZING SHEET STRUCTURES WITH RESPECT TO BUCKLING ADRIAN MÅHLÉN 93720 PAINTED BODY & CLOSURES

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- 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



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



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


Thank you for listening

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Please ask any questions you may have


Documents

Volvo cars optimization arena - Chalmers · 2016-11-30 · 2 Agenda - Volvo cars optimization arena - Wheel suspension cluster - Individual thesis presentations - Lessons learned