Structural development of passenger cars to achieve crashworthy performance through virtual testing using simulation tools has been the way forward for automotive industry currently. Simulating a crash load case like offset frontal impact requires comprehensive model building as it involves complex interaction between different vehicle aggregates to be accurately simulated. Hence to develop the vehicle structure for frontal impact requirements through virtual environment it is important that confidence, on crash FE model and subsequently the proposed vehicle design, needs to be developed though a step by step development approach. One such CAE based systematic product development methodology is explained in the present paper as applied on a sport utility vehicle to meet ODB56 crash performance requirements as per ECE R94. The proposed methodology stands in-between a rigorous DOE approach of vehicle development and the conventional approach which might lead to surprises in the physical test. The paper also highlights the need for improving full vehicle FE model representation close to physical prototype with detailed sub-assembly modeling, incorporating manufacturing effects (e.g. thickness variation, work hardening effects due to forming process etc) and other System variability (e.g. material property scatter) on to the crash CAE model. The sole aim of proposed CAE based product development methodology is to predict vehicle crash performance with high level of confidence and develop the structure to meet the crash performance requirements first time right thus reducing overall product development time and cost.
CAE based product development methodology for frontal impact requirements
Crash.tech, 2012 ; 26/1-26/5
2012
5 Seiten, 5 Bilder, 2 Quellen
Aufsatz (Konferenz)
Englisch
CAE based product development methodology for frontal impact requirements
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