Vehicle Proving Ground Durability Performance Simulation using Flexible Multi-Body Dynamic Modal Stress Synthesis Method

2012 International Ground Vehicle Users Symposium

Presented By: Maolin Tsai General Motors Company

October 19, 2012

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2012 International Ground Vehicle Users Symposium

Outline
Objectives Flow Chart of the Flexible Multi-Body Dynamic Modal Stress Synthesis for Dynamic Durability Analysis

Flexible Multi-Body Dynamic Durability Analysis in Chassis Applications

Methodologies Verification: Fatigue Damage

Motivations: Failure Mode Correlation

Accelerated Test Development Conclusions

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Objectives
Dynamic stress simulation to account Effective structural design for durability

for inertia effect (dynamic equilibrium & satisfy both the geometric (critical for component with large deformation or rigid body motion articulation) and force boundary conditions .
Inertia Relief based fatigue analysis (may mislead design) Examples: compound crank rear axle & suspension links FEA-based modal or direct transient fatigue analysis (not practical) Practical and efficient approach for

optimization.
Standard quasi-static design loads Road load based duty cycle loads

Accelerated laboratory development.

Multi-axial subsystem block cycle test (instead of using RPC test) or

component bench tests

dynamic fatigue analysis & synthesis. No additional simulation effort is required compared with traditional dynamic load prediction (incorporating flexible body into multi-body dynamic model)
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Flow Chart of Duty Cycle Flexible Multi-Body Dynamic Durability Analysis

Build up flexible multi-body dynamic model (w/mtx file); and with modal stress requested in FE solver for post-process

Multi-body dynamic model for vehicle durability load prediction

Vehicle proving ground durability road load schedules

(i) Interface joint loads/disp. output (ii) Modal coordinate output

Modal stress synthesis

Flexible body dynamic stress history output

Fatigue material data base

Duty cycle modal frequency fatigue analysis

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Flexible Multi-Body Dynamic Modal Stress Synthesis for Chassis Durability Application Examples
Theory: Craig-Bampton Component Mode Synthesis (CMS) It combines the motion of joint interfaces with normal modes of the structural components

Front Cradle and Rear Compound Crank

Independent Suspension Links

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Dynamic Rear Links Stress Animation of Pothole Load

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Full Vehicle Dynamic Stress Animation of Rough Road Event

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Methodologies Verification
Torsional Beam Fatigue Damage Correlation

Fatigue analysis using flexible multi-body dynamic modal stress synthesis

Fatigue analysis using modal transient method

Good Correlation: The peak damage ratio between the two methods is 1: 1.6

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Motivations: Failure Mode Correlation

1. Dynamic Inertia Effect 2. Boundary Conditions
critical location predicted using Flexible multi-body dynamic modal stress synthesis critical location predicted using inertia relief stress analysis

Spring Block Cycle Load (cant correlate test failure mode)

Spindle Lateral Load (Modal Stress Synthesis) (correlate test failure mode)

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Application: Multi-Axial Subsystem Block Cycle Accelerated Test Development

Integration of Flexible Multi-Body Dynamic, Fatigue and Optimization in Accelerated Test Development

(ADAMS/Flex Modal Frequency Method) (ADAMS/Flex Modal Frequency Method)

Baseline Road Loads Structural Damage (i) Wheel Forces & Suspension Interface Pseudo-Fatigue Damage (ii) Structural Fatigue Damage Using ADAMS/Flex Modal Frequency Method

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Application: Multi-Axial Subsystem Block Cycle Accelerated Test Development (Cont.) Damage Correlation of Rig Test Interface Loads

Rig Test Input: 10 channels Wheel Force

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Conclusions
The flexible multi-body dynamic modal stress based durability analysis and synthesis is a key enabler for vehicle durability development process in terms of efficiency and effectiveness. The amount of extra computation time and effort is low and yet the accuracy of life prediction is greatly enhanced compared to traditional methods.

Multi-axial subsystem block cycle accelerated test using this methodology can significantly reduce test time (compared with RPC test) and still retain the damage content in the critical locations.

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Contributors

Hyung-Joo Hong Robert L. Geisler Glenn Babiak General Motors Company

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