Simulation-Based Fatigue

Analysis using RecurDyn

And FEMFAT
| Karl Bangert | Jim Wenson | Taero Cha| FunctionSim LLC | 15Oct08 |

FunctionSim, LLC 2008

The RecurDyn Advantage

MAGNA RecurDyn Collaboration
Generating Virtual Powertrain Loads
Single Cylinder Engine Case Study
Summary / Action Items

FunctionBay
GmbH
2007
FunctionSIM
LLC 2008

Teams have been challenged to improve their

design processes
Simulation & Analysis are established methods
of troubleshooting design problems
Moving Simulation to the design phase can:
Reduce

Design &
Testing Time & Costs
Bring it all Together!

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2007
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Established Customer Base

Worldwide Growth & Support
Fast, Robust Simulation Solutions
Cutting-Edge Multi-Physics Technology

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FunctionSim LLC
Full

Service RecurDyn Distributor

Software

Sales and Technical Support

Engineering
US

Services

Owned and Operated

Close

ties to FunctionBay GmbH and FunctionBay Korea

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Automotive

Tracked Vehicles

US Army
TACOM

General Machinery

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Motorsports

Media Transport

Worldwide >250 Commercial Customers > 2000 Engineering Seats

75% belong to Fortune Top 500 Companies FunctionBay
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Cub Cadet i1000 - Zero Turn Radius Mower

MTD Products
Advanced Kinematics
Simulation for Design
Featured in Popular Science
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Joe Gibbs Racing

Engine Dynamics Test & CAE
Looking to Maintain Competetive Edge
Simulating Car of Tomorrow

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Solid Elements

FunctionBay
GmbH
2007
FunctionSIM
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The RecurDyn Advantage

MAGNA RecurDyn Collaboration
Generating Virtual Powertrain Loads
Single Cylinder Engine Case Study
Summary / Action Items

FunctionBay
GmbH
2007
FunctionSIM
LLC 2008

Enhanced Dynamic Simulation by

Combining FEA and MBS

Finite
Element
Analysis (FEA)

Linear, elastic
structures (many DOF)
Simulations with
nonlinearities like
bushings or large
movements are not
efficient.

Multi Body
Simulation
(MBS)

To rigid bodies
(few DOF) limited

Efficient simulations
with nonlinearities like
bushings or large
movements.

Combined
FEA and
MBS

Models with included

large, linear FE
structures

Efficient simulations
with nonlinearities like
bushings or large
movements.

FunctionBay
GmbH
2007
FunctionSIM
LLC 2008

NASTRAN /
ABAQUS

Dynamic Simulation by
FEA MBS FEMFAT
Build
FE
model
of
flexible
body
Build
FE
model
of
flexible
body
define interface points

FE
modal
analysis
FE
modal
analysis
component modes, component mode stresses

Import
FE
-- structure
into
MBS
Import
FE
structure
into
MBS
connect flexible body to rigid bodies

FEMFAT

ADAMS /
RECURDYN

define interface points

component modes, component mode stresses

connect flexible body to rigid bodies

output time series of modal response

4
Solve
hybrid
FE-MBS-EHD
system
Solve
hybrid
FE-MBS-EHD
system

output time series of modal response

5
Import
modal
loads
into
FEMFAT
Import
modal
loads
into
FEMFAT

modal stresses, time series modal response

modal stresses, time series modal response

includes contribution of static and vibration loads

6
Multiaxial
Fatigue
Analysis
in
FEMFAT
Multiaxial
Fatigue
Analysis
in
FEMFAT

includes contribution of static and vibration loads

FunctionBay
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2007
FunctionSIM
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Oil Film Model (EHD)

Oil film

differential fluid element

d
x

dz

dy

dx

inclined position of pin

Navier Stokes Equation

H(,z) .... lubrication gap g

Reynolds differential equation:

3 p D 3 p 6 H
H
+2
H
+

H
= 2 B
B Z Z

partial elliptic diff. equation

numerically solved (highly optimized)

Squeezing and expulsion of oil film

and dyn. deformations of bearing shell
and pin due to local pressure inside
bearing

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2007
FunctionSIM
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Integration of EHD in MBS

Co-Simulation process:

MBS

Bearing settings

force & torque

Diameter
Width
Clearance
Oil viscosity

EHD

(Lubricating grooves)
(Oil in-/outlets)

positions & velocities:

Optional outputs
Journal position and velocity (dislocation orbits)
Pressure distributions at definable intervals
Bearing forces und torques

FunctionBay
GmbH
2007
FunctionSIM
LLC 2008

Modelling Principle
Crankshaft (flex. body)
Rigid bearing shell
Oil film model:

Connecting
bearing shell and
User
written
crankshaft
subroutine
Output:
force and
torque acting
between
linearized
stiffnessbearing
of
bearingshell
housing
and crank

FunctionBay
GmbH
2007
FunctionSIM
LLC 2008

Fatigue - based on modal stresses

E Tensor

(t
)

q1(t)

q2(t)

1
E Tensor

2
E Tensor

q1(t)

q2(t)

(t
1
2
)
(t)
... Total deformation of flexible body at time t
... Mode shape (FEA result, time invariant) qi(t)
Component
Modes
...
Contribution
of each mode to the total
deformation at time t. (MBS result, skalar
(t)
...for
Total
stress
state
ofdependent)
flexible body at time t
each
mode,
time
i
... Stress distribution of single mode shape (FEA

result, time invariant)

i

FunctionBay
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2007
FunctionSIM
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Fatigue Analysis based on

Modal StressesMBS

Component Modes

and
(E)HD
(Co - Simulation)

Modal
Coordinates
q1(t)

FEMFAT

Channel 1

q1(t)

q2(t)
Channel 2

qn(t)

q2(t)

Fatigue

ADAMS Spreadsheet
or User-Subroutine

FEA

Channel n

Modal Stresses

e.g.: NASTRAN OP2-file

qn(t)

Additional

Load Cases

(Screwing,...)

FunctionBay
GmbH
2007
FunctionSIM
LLC 2008

The RecurDyn Advantage

MAGNA RecurDyn Collaboration
Generating Virtual Powertrain Loads
Single Cylinder Engine Case Study
Summary / Action Items

FunctionBay
GmbH
2007
FunctionSIM
LLC 2008

MFBD Driveline Model

Large

Displacements
Local Deformations & Stresses

FunctionBay
GmbH
2007
FunctionSIM
LLC 2008

Input Drivers

Rigid Driveline Model

at 6degree Inclination
Flexible NASTRAN
model of transmission
Housing (74000 DOF)
Torque Input to
Driveshaft
2hrs CPU for 0.6 sec
transient simulation

System Outputs
+ Responses

FunctionBay
GmbH
2007
FunctionSIM
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Conclusion & Discussion

Dynamic fatigue analysis of a
crank shaft is necessary due to
occuring system resonances
Engine run-up to detect all
system resonances within the
engine rpm range;
Fatigue results within the
whole engine rpm range
Damping dominates system
response in a resonance state:
detailed information needed
(e.g. damper, flywheel, clutch
....)
Dynamic fatigue analysis can be performed in reasonable simulation time
Detailed analysis of crank train dynamics / resonances to improve the design
FunctionBay
GmbH
2007
FunctionSIM
LLC 2008

The RecurDyn Advantage

MAGNA RecurDyn Collaboration
Generating Virtual Powertrain Loads
Single Cylinder Engine Case Study
Summary / Action Items

FunctionBay
GmbH
2007
FunctionSIM
LLC 2008

Engine Performance
Torsional

Vibrations and Bearing Loads

FunctionBay
GmbH
2007
FunctionSIM
LLC 2008

Engine Performance
Bearing

Loads versus Time

FunctionBay
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2007
FunctionSIM
LLC 2008

Engine Performance
Crankshaft

Velocity versus Time

FunctionBay
GmbH
2007
FunctionSIM
LLC 2008

Channel Definition

FunctionBay
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2007
FunctionSIM
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Visualization Channel History

FunctionBay
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2007
FunctionSIM
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Visualization S-N-Curves

FunctionBay
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2007
FunctionSIM
LLC 2008

Visualization Haigh-Diagramm

FunctionBay
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2007
FunctionSIM
LLC 2008

Visualization Equivalent Stress History

FunctionBay
GmbH
2007
FunctionSIM
LLC 2008

Visualization Results

FunctionBay
GmbH
2007
FunctionSIM
LLC 2008

Cranktrain Modeling
Global

Layout:

Inline, V-eng, boxer, N-cylinder

Component

Wizards:

Pistons, Cylinders, Rods, Block

Crankshaft (rigid, torsional, beam)
Contact

Modeling:

Piston/Cylinder Bore Input

Auxiliary

Components:

Flywheel, Balancer Shafts,

Equivalent Drive Train,
Torsional Damper
FunctionBay
GmbH
2007
FunctionSIM
LLC 2008

Crankchaft Modeling
Global

Layout:

Inline, V-eng, boxer, N-cylinder

Component

Wizards:

Pistons, Cylinders, Rods, Block

Crankshaft (rigid, torsional, beam)
Contact

Modeling:

Piston/Cylinder Bore Input

Auxiliary

Components:

Flywheel, Balancer Shafts,

Equivalent Drive Train,
Torsional Damper
FunctionBay
GmbH
2007
FunctionSIM
LLC 2008

Crank Train Simulation

Torsional Vibrations
Bearing Loads
Coupling to Timing Chains
and Valvetrains
Flexible Layouts
.

FunctionBay
GmbH
2007
FunctionSIM
LLC 2008

Summary and Discussion

FunctionBay
GmbH
2007
FunctionSIM
LLC 2008