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Introduction To FEA/FEM
EIMA RACE 2014
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FEA PROCESS
Pre Process HyperMesh
Modeling
FEM
Creates meshing
Assigning material and element property
Simulation setup (loading and boundary condition)
Solving Optistruct/Radioss
Post Process HyperView/HyperGraph
Review results
Visualization
Introduction to Meshing
Discretization
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Engine & Chassis - OptiStruct Linear Static to determine the global stiffness
behaviour of the model, this include the global torsion & bending.
- modal analysis, to understand the first mode frequency, to better
understand the dynamic response of the structural before details design &
fabrication.
Crash Box and Anti-Penetration Plate or Full car impact crash Radioss
Block: Front Crash and measure the intrusion. This can be useful for safety
evaluation.
Bodywork & Overhang Frequency response can be implemented here
Concept Design - Solid Thinking Inspire
More infos..
http://www.altairuniversity.com
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OPTIMIZATION FLOWCHART
OPTIMIZED DESIGN
CONCLUSION
CAE analysis and optimization tools save development time
and reduce costs in the conceptual design phase for new and
failed parts. Topology optimization has the highest
importance in the development process of all optimization
methods as it works in the very early phase of the design
process.
Application of optimization technique using OptiStruct on
this profile resulted in a weight reduction of 142gram and
maximum stress is 10.5mpa. This show that the new design
is lower in weight and have higher strength.
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ABSTRACT
Sheet metal forming operations are one of the most common technological processs, but still the tool and the process
design is a difficult task. The most frequent defect in sheet metal forming operation is material breakage, wrinkling and
shape defect due to spring back. Numerical simulation aids in evaluating the product manufacturability and predicting the
defect in the early stage, thus minimizing the time and cost for a process development and production (Mangesh
Dagwar,Y.N. Yadav 2005).
This project aims to develop a methodology for accurately predicting and forecast of forming effect in design process to
reduce product variation through Finite Element Method (FEM). Through Altair HyperForm application we can identified
formability effect such as wrinkle, crack or fracture and compare with actual try out.
Determination of
design factor
Geometric
definition (CAD)
Ongoing
Review
Literature
1.
0.19mm
45.2% = 0.18mm
No.
1.
0.29mm
45.2% = 0.27mm
Project material
selection
Model FE Analysis
approach
CONCLUSIONS
From the results, the formability result between actual try out and
virtual try out can be investigate, verified and evaluate before final
modification of the tool geometry.
Some findings of the project are summarized as follows:
1. Element mesh from simulation generates result of crack and
wrinkle that occur at product that can be comparing with actual
try out
2. Greater blank holder force will induce greater stress especially
at the necking radius region and the stress distribution will spread
wider along the metal sheet.
3. An incremental analysis had been done, it show very significant
on to the sheet metal flow whereby it predict base on actual case.
4. Binder force or (BHF) and shoulder radius shall be specially
designed in order to maintain a smooth flow of material to
maintain a good quality of final product.
No
Satisfied/
Objective
achieved?
Yes
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