2011 ALTAIR

(CAx- )
: ( 4) ( 3)

: ( )
CAx-based Design Lab.

Contents
1 Assigned Subject(A) 2 Battery tray design

Introduction Boundary condition Step1_Optimization Topology Step2_Optimization Topology Step3_Optimization Topology Final Detail analysis

Free Subject Light-weight design homemade car frame considering safety Introduction Boundary condition Step1_Optimization Topology Step2_Optimization Size Final Detail analysis Attachment
2
CAx-based Design Lab.

Optimization Topic A
Battery tray design

CAx-based Design Lab.

Introduction
Target

Optimum Target!

Design object

Optimization in order to decrease the displacement a certain frequency range.

4
CAx-based Design Lab.

Optimization procedure

Step1 Topology

Step1 Remodeling

Initial design

Step2 Topology

Final - Design

step2 Remodeling

Step3 Topology

CAx-based Design Lab.

Boundary conditions
Material Property Component Steel Battery tray Youngs modulus (MPa) 2.07e+05 Poisson ratio 0.26 Density (N-s/mm4) 7.9e-09 Type Element PSHEEL Avg. Size 5mm

Thickness Design 2mm Non-design 2mm

Red : Non design Sky Blue : Vertical-Non design Blue : Design space

All Fixed

40 mm

220 mm 298 mm

*
Loading point (A) Z axis 50N-DAREA apply

CAx-based Design Lab.

Boundary conditions (contd)

Analysis conditions
Perform FRF analysis
Modal method (Lanczos) - EIGRL (0~3000 Hz) TABLED1 (LINEAR) - x(1):0 , y(1):50 , x(2):1000 , y(2):50 RLOAD2 : EXCITE - FORCE (Z axis 50N - DAREA), TB - TABLED1

Dynamic loading apply

Dynamic loading

Frequency
0 ~ 1000Hz, Number of mode : 21
Data point (pt B)

Load case
Type : freq. resp (modal) Point of center area

Measuring point from pt B

*
Top view

CAx-based Design Lab.

Base analysis
From base analysis result
Constraint condition(disp.) 0.25 mm
Displacement at pt B( Max. : 0.345 mm) > Constraint(0.25 mm)

Freq
(Hz) 0 50 100 150

Disp.
(mm)

Freq
(Hz)

Disp.
(mm)

0.259 0.260 0.094 0.077

550 600 650 700 750 800 850 900

0.009 0.032 0.014 0.009 0.013 0.021 0.015 0.008

200
250 300 350

0.345
0.124 0.043 0.023

pt B

400
450 500

0.015
0.038 0.032

950
1000

0.009
0.009

200Hz Value (0.345mm) > 0.25mm

CAx-based Design Lab.

Topology optimization
Optimization setup for topology design
Objective function : Min. Mass Constraint condition : UB 0.25mm (at pt B)

pt B

Topology optimization conditions

Type : PSHELL Initial(Base) thickness : 2mm Using pattern grouping

CAx-based Design Lab.

Step1. Topology optimization

Effect of patterns
none
(Unit : mm)

cyc 1-pln (ucyc = 4)

(Unit : mm)

3-plns sym
(Unit : mm)

3.95 3.92 0
0.35 Magnitude 0.3 0.25 0.2 0.15 0.1 0.05 0 0

3.934 3.913

0.54% up

3.95 3.92

3.913

3.926

0.33% up 3.95 3.92 3.913

3.938

0.64% up

Mass (kg)
Max Disp. : 0.345mm

0
0.35 Magnitude 0.3 0.25 0.2 0.15 0.1 0.05 0

Mass (kg)
Max Disp. : 0.345mm

0
0.35 Magnitude 0.3 0.2 0.25 0.15 0.1 0.05 0

Mass (kg)
Max Disp. : 0.345mm

27.68% down
Max Disp. : 0.250mm

27.62% down
Max Disp. : 0.251mm
Base Cyc 1-pln

27.62% down
Max Disp. : 0.250mm

Base

Base 3-plns sym

none

50

100 150 200 250 300 Frequency

50

100 150 200 250 300 Frequency

50

100 150 200 250 300 Frequency

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CAx-based Design Lab.

Step1. Topology optimization (contd)

Step1. Topology optimization result

Freq
(Hz) 0

Disp.
(mm)

Freq Disp.
(Hz) (mm)

0.244

550 600 650 700 750 800 850 900 950 1000

0.006 0.035 0.018 0.011 0.016 0.019 0.015 0.008 0.008 0.010

50
100 150 200 250 300 350 400 450 500

0.251
0.096 0.082 0.249 0.117 0.046 0.027 0.013 0.038 0.046

pt B

50Hz Value (Max. : 0.251mm) > UB (0.25mm)

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CAx-based Design Lab.

Step1. Topology optimization (contd)

Re-modeling plan
Added thickness : 2mm Solid element
Initial design

19.5 mm 30 mm
RE modeling

2 mm

19 mm 125 mm

Rib

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CAx-based Design Lab.

Step2. Topology optimization

Re-topology optimization result
Analyze only the re-design excluding initial design
Re-topology

Excluding

Freq
(Hz)

Disp.
(mm)

Freq Disp.
(Hz) (mm)

Design area

0
50 100

0.250
0.226 0.099

550 600 650

0.009 0.044 0.021

150

0.084

700
750 800 850 900 950 1000

0.015
0.023 0.019 0.011 0.006 0.007 0.009

200
250 300 350 400 450 500

0.250
0.120 0.048 0.026 0.014 0.039 0.044

pt B
Iteration 39

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Mass : Initial (3.913kg) Re-topology (3.935kg) CAx-based Design Lab.

Step3. Re-modeling & Final topology optimization

Re-modeling & Topology optimization
Re-modeling Opt. Result

Non-design
Left Right

Design area
Dimension for final modeling

Bottom

38.7mm 9.6mm
Re-modeling Bottom

96.2mm

Consider forming

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CAx-based Design Lab.

Result for final optimization

Analysis result for final modeling
Initial

Freq
(Hz)

Disp.
(mm)

Freq
(Hz)

Disp.
(mm)

pt B

0
50 100

0.246
0.227 0.099 0.086 0.229 0.117 0.051 0.027

550 600 650 700 750 800 850 900

0.008 0.044 0.022 0.015 0.023 0.018 0.012 0.006

3.94 3.935 3.93 3.925 3.92 3.915 3.91 3 3.905 0 3.9

3.933

3.935

3.938

150

3.913

Mass (kg) Initial : 3.913 Final : 3.938

200 250 300 350

400
450
Initial step1 step2 Final

0.015
0.039 0.048

950
1000

0.007
0.009

15

500

CAx-based Design Lab.

Free Subject
Light-weight design home-made car frame considering safety

16

CAx-based Design Lab.

Introduction
Target

Buggy CAR

KSAE_BAJA CAR
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CAx-based Design Lab.

Optimization procedure

Step1 Topology
Step1 Remodeling

Initial Design

Final Result Step1 Re Topology

Step2 Beam Modeling 18 & Size Optimum

CAx-based Design Lab.

Analysis conditions
Material Property Youngs modulus (MPa) 2.07e+05 2.2e+03 2.0e+02 Poisson ratio 0.26 0.38 0.49 Density (kg/mm) 7.9e-09 1.2e-09 2.0e-09 YS (MPa) 289 UTS (MPa) 454 Mass dumping (kg)

Component Steel Plastic Rubber Frame Seat Tire

Using rigid-body & Mass element for approximate massive component

Please follow that arrow.

DU KSAE Baja car

Human(80kg) Steering(3kg) Engine(20kg)

Sproket & CVjoint(20kg)

Wheel & Brake Assy & Tie Rod 130kg(Total)

19

CAx-based Design Lab.

Boundary conditions
Why analyze the linear static idea?
Optistruct just treats linear static - (Unable to consider dynamic problem) Calculation of static force Simplify the test case of a crash & Stiffness
Crash : Front, Side, Rear, Roof (10,000N) Stiffness : Bending, Torsion (20,000N)

Rigid spider distribute force - Crash Concentrated load - Stiffness

Non-Linear

mv v = 50km/h = 13.89m/s F= t t = 0.5s

Postulate ( V & T )

m = 350kg (DU baja car)

F
Linear

350kg 13.89m / s 10,000 N 0.5s

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CAx-based Design Lab.

Boundary conditions (contd)

Force & B.Cs
DOF X&Y&Z DOF Z DOF Y&Z Torsion stiffness DOF Z

DOF Y&Z
Bending stiffness

DOF Z Force & B.Cs view

DOF X&Y&Z

Stiffness force & B.C ALL Fix Roof crash

Rear crash

Front crash

Side crash ALL Fix

21 Crash force & B.C

CAx-based Design Lab.

Step1. Topology optimization

Setup for topology optimization
Objective function : Min. Weighted compliance 6

i=1

w ici ( w i = 1)
Symmetry

Optimum parameters : 90 mm member size 180 mm Constraint Conditions : Mass fraction 0.1 , 0.2 , 0.3

Topology optimization conditions

Draw type : Y Direction (Split) Pattern grouping : 1-pln sym

Y Axis Direction

Draw

Draw type & Pattern grouping

22

CAx-based Design Lab.

Step1. Topology optimization (cont`d)

10 % Mass fraction

Remodeling

Optimum Result (Mass10%)

20 % Mass fraction

Load case
Front Crash Side Crash Rear Crash Roof Crash Torsion Stiffness Bending Stiffness

Max Stress (MPa)

Max Disp. (mm)

5.804 4.550 3.116 2.818 4.579 2.832

8.761 11.61 4.843 0.7455 0.8894 0.3499

Initial Structure 30 % Mass fraction

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CAx-based Design Lab.

Step1. Topology optimization (cont`d)

Setup for Re-topology optimization
Objective : Min. Mass Static Disp. Constraint 5mm
Front & Rear & Side & Roof Crash

Design result

Re - Optimum result
Load case
Front Crash Side Crash Rear Crash Roof Crash Torsion Stiffness Bending Stiffness Remodeled & FE system
Max Stress (MPa) Max Disp. (mm)

17.45 21.82 19.66 68.82 57.83 53.75

1.398 6.256 1.036 1.944 3.491 0.8874

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CAx-based Design Lab.

Step2. Size optimization

Size optimization with beam modeling
Delete unnecessary component Added design : Lower & Upper arm Beam section : Rod
Von mises stress constraints 200 MPa Ranged from 5mm to 20mm by 1mm Von mises stress constraints 900 MPa Ranged from STKM Radius (mm) 5 6
Increments 1mm

7 19 20
Rod type

Beam section : Tube

Radius(mm) Out In(1.2T) In(1.5T)

11.1 12.7 14.3 15.9 19.05 10.5 12.1 13.7 15.3 18.45 10.35 11.95 13.55 15.15 18.3

Re-Optimization result

Beam modeling

Tube type STKM CAx-based Design Lab.

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Step2. Size optimization (cont`d)

Size optimization result
Increment size

Upper & Lower arm

Side member cage

Cage of driver seat

Steering & engine room cage

Component mounting cage

Rod result
Property Diameter(mm)

Tube result
Property Out/In Diameter(mm)

Upper & Lower arm Side member cage Cage of driver seat Steering & Engine room cage Component mounting cage ROD TYPE

20 34 26 26 36

Upper & Lower arm Side member cage Cage of driver seat Steering & Engine room cage Component mounting cage TUBE TYPE

22.2/20.7 (1.5T) 28.6/27.1 (1.5T) 28.6/27.4 (1.2T) 28.6/27.4 (1.2T) 31.8/30.3 (1.5T)

Using VIEW TEXT Max Diameter : 36mm . Prop

Min Diameter : 20mm

Max Diameter : 31.8mm(out), 30.3(In) Min Diameter : 22.2mm(out), 20.7(In)

26

CAx-based Design Lab.

Step2. Size optimization (cont`d)

Result for size optimization
Initial size(Tube Diameter) : 25.4mm(Out) 1.2T Initial size(Rod Diameter) : 10mm

Tube type Mass(ton)

Size Optimization Result (Beam model) Rod
Load case Front Impact Side Impact Rear Impact
Max Stress (MPa) Max Disp. (mm) Max Stress (MPa)

Tube
Max Disp (mm)

97.76 175.5 81.04 175.3 164.4 143.8

21.94 71.85 18.74 6.775 8.712 1.554

688.3 1044 445.2 1272 1266 1065

11.53 22.42 10.03 53.70 99.01 9.228

Rod type Mass(ton)

Roof Crash Torsion Stiffness Bending Stiffness

27

CAx-based Design Lab.

Step3. Final detail analysis

Detail analysis
Rod type : Solid element Tube type : Shell element

Beam Element

Solid & Shell model

28

CAx-based Design Lab.

Step3. Final detail analysis (cont`d)

Tube in comparison with rod (Detail analysis result)
Select tube type for the benefit of light-weight
Displacement(mm) Stress (MPa)

Average Ratio : 7.3

Average Ratio : 6.7

Tube / Rod = Ratio

Step1 Re / Rod & Tube = Ratio

Disp. Result (mm)

Load case
Front Impact Side Impact Rear Impact Roof Crash Torsion Stiffness Bending Stiffness Tube Rod Ratio

Stress. Result (MPa)

Load case
Front Impact Side Impact Rear Impact Roof Crash Torsion Stiffness Bending Stiffness Tube Rod Ratio

Mass Result (kg)

Mass 1step 1step_Re

10.3 20.2 9.2 40.4 69.5 8.1

1.6 6.7 1.5 4.1 7.4 0.9

6.4 3 6.2 9.8 9.4 8.9

1051 1757 755.3 3560 2433 1250

133 226.2 84.9 625.9 452.5 282.3

7.9 7.8 8.9 5.7 5.4 4.4

960.4 508.5

5.6
Tube
90.7

Ratio

1.9
Rod
265

29

CAx-based Design Lab.

Step3. Final detail analysis (cont`d)

Confirmation of passenger injury
Checking frame design
Displacement by Crash Distance between frame and dummy

Teammate Mr. Nam

310 mm 300 mm

400 mm

280 mm 50 mm 600 mm

select

300 mm 520 mm 410 mm

Problem Length
Type Length (mm) Crash Front 10.3 (X axis) Distance 50

Side
Roof Rear

20.2 (Y axis)
40.4 (Z axis) 9.2 (X axis)

75
80 20

Crash Result30Distance between Displacement frame & dummy

CAx-based Design Lab.

31

CAx-based Design Lab.

Attachment
Step1_Topology result (10 % mass fraction)

Front Impact

Side Impact

Roof Impact

Bending Stiffness

Torsion Stiffness

Rear Impact

Displacement (mm)

Front Impact

Side Impact

Roof Impact

Bending Stiffness

Torsion Stiffness

Rear Impact

Von mises stress (MPa)

32

CAx-based Design Lab.

Attachment
Step1_Re-topology result

Front Impact

Side Impact

Roof Impact

Bending Stiffness

Torsion Stiffness

Rear Impact

Displacement (mm)

Front Impact

Side Impact

Roof Impact

Bending Stiffness

Torsion Stiffness

Rear Impact

Von mises Stress (MPa)

33

CAx-based Design Lab.

Attachment
Final result contour view (Tube type 2D)

Front Impact

Side Impact

Roof Impact

Bending Stiffness

Torsion Stiffness

Rear Impact

Displacement (mm)

Front Impact

Side Impact

Roof Impact

Bending Stiffness

Torsion Stiffness

Rear Impact

Von mises Stress (MPa)

34

CAx-based Design Lab.

Attachment
Final detail analysis_Rod type result (3D)

Front Impact

Side Impact

Roof Impact

Bending Stiffness

Torsion Stiffness

Rear Impact

Displacement (mm)

Front Impact

Side Impact

Roof Impact

Bending Stiffness

Torsion Stiffness

Rear Impact

Von mises Stress (MPa)

35

CAx-based Design Lab.

Attachment
Step2_Rod type result (1D)

Front Impact

Side Impact

Roof Impact

Bending Stiffness

Torsion Stiffness

Rear Impact

Displacement (mm)

Front Impact

Side Impact

Roof Impact

Bending Stiffness

Torsion Stiffness

Rear Impact

Von mises Stress (MPa)

36

CAx-based Design Lab.

Attachment
step2_Tube type result (1D)

Front Impact

Side Impact

Roof Impact

Bending Stiffness

Torsion Stiffness

Rear Impact

Displacement (mm)

Front Impact

Side Impact

Roof Impact

Bending Stiffness

Torsion Stiffness

Rear Impact

Von mises Stress (MPa)

37

CAx-based Design Lab.

Attachment
Tube type Stiffness variable result

3000N Apply

4000N Apply
Displacement(mm) Von Mises Stress (MPa) Displacement(mm) Von Mises Stress (MPa)

Bending Stiffness

Torsion stiffness

38

CAx-based Design Lab.