Fatigue Analysis of Flexible Bodies with AVL EXCITE, FEMFAT and ABAQUS using Modal Data

21 Pages·2014·1.82 MB·English

Fatigue Analysis of Flexible Bodies with AVL EXCITE,
FEMFAT and ABAQUS using Modal Data Recovery
Peter Van Wieren, Senior Technical Specialist
AVL PEI
Dynamic Simulation in Vehicle Engineering
3rd International Conference 2014
INTRODUCTION
(cid:1)
General overview of AVL and the AVL EXCITE engine simulation software
(cid:1)
Description of a new feature of AVL EXCITE which allows the use of modal stress
recovery with the ABAQUS FE software and Magna-Steyr’s FEMFAT fatigue analysis
software.
AVL PEI 2
THE GLOBAL NETWORK OF AVL POWERTRAIN
ENGINEERING & PEI
AVL Technical Centers
Sweden
Germany
United Kingdom
Plymouth & Ann Arbor, MI
Austria- World HQ
China
Belgium
Czech Republic
Lake Forest, CA
France Poland
Russia
Iran
Spain Hungary
Indonesia
Turkey Thailand
Croatia
Mexico Italy
Slovenia Switzerland Japan
India
Korea
Brazil
Malaysia Taiwan
Argentina
AVL Plymouth Technical Center: PEI – Consulting
(cid:2) Structural & dynamic analysis
(cid:2) Thermodynamics & CFD
(cid:2) Design
(cid:2) Engine development
(cid:2) Mechanical development
(cid:2) ….
AVL PEI 3
AVL‘S SIMULATION SOFTWARE IS LEVERAGING FROM THE
SYNERGIES OF ALL AVL BUSINESS UNITS
AVL PTE
Powertrain
Engineering
passenger cars 2-wheelers racing
AVL AST
Advanced
Engineering Simulation
Technologies
construction agriculture commercial vehicle
AVL ITS
Instrumentation
Testing and
Test Systems
locomotive marine power plants
AVL PEI 4
AREA OF APPLICATION
(cid:1)
Cranktrain and powertrain design in the
concept phase (EXCITE Designer)
(cid:1)
Hydrodynamics bearing analysis
(cid:1)
Torsional crankshaft vibrations
(cid:1)
Crankshaft strength analysis
(cid:1)
Transient strength analysis
(cid:1)
Crankshaft
(cid:1)
Connecting Rod
(cid:1)
Piston
(cid:1)
Main Bearing Wall
(cid:1)
Flywheel Whirl
AVL PEI 5
AREA OF APPLICATION
(cid:1)
NVH of power units
(cid:1)
Low frequency vibration analysis
(engine mounts)
(cid:1)
Radiated noise
(cid:1)
Turbocharger and accessories
(cid:1)
Advanced EHD contact simulation
(cid:1)
Slider bearing design
(cid:1)
Slider bearing failure
(cid:1)
Piston-liner contact analysis
(cid:1)
Detailed investigation in friction losses
(cid:1)
Dynamics / acoustics of transmissions and
drivelines
(cid:1)
Analysis of in-stationary conditions
(cid:1)
High frequency noise phenomena
AVL PEI 6
EXCITE CRANKSHAFT STRENGTH ANALYSIS –
PROVEN FOR ANY ENGINE SIZE
10000
V10 Racing 9 Cyl. Marine
V10 Diesel
1000
V6 Gasoline
]
W
k
[
-

r
e
w W12 Gasoline
o
P
I4 Diesel
100
V16 Marine
I4 Diesel
I4 Gasoline
V8 Marine
1 Cyl. Motorcycle
I4 Gasoline
10
1 10 100 1000
Displacement - [L]
AVL PEI 7
OVERVIEW OF AVL EXCITE
MULTIBODY DYNAMIC SIMULATIONS
Flexible MBS under transient conditions:
Vibrating Vibrating, Rotating,
Structure Parts Oscillating Structure Parts
(cid:1)
Flexible bodies represented by linear
Nonlinear Bearing
Forces and Moments
calculated due to FE models, such as:
Actual Dynamics of
Parts
(cid:1)
Engine Block
Radial Slider Bearing,
Axial Thrust Bearing,
Piston / Liner Contact, (cid:1)
Crankshaft
Rotational Coupling, ...
(cid:1)
Connecting Rod
Excitation Forces and Moments
(cid:1)
Non-Linear Joints: connect the rigid
Gas Excitation bodies, such as:
(cid:1)
Simple Joints (e.g. Revolute)
Valve Train Excitation
(cid:1)
Engine Mounts
Piston Slap
(cid:1)
Highly complex thermo elasto-
hydrodynamic joints including
Excitation from Injection System mixed lubrication
(cid:1)
Excited by external forces
AVL PEI 8
OVERVIEW OF AVL EXCITE
MULTIBODY DYNAMIC SIMULATIONS
The EXCITE Solver computes and
evaluates the equations of motion in the
time domain for several engine cycles.
Results include:
(cid:1)
Vibrational motion of the flexible
bodies.
(cid:1)
Forces associated with each joint.
(cid:1)
EHD results:
(cid:1)
Clearances
(cid:1)
Pressure distributions
(cid:1)
Temperatures
(cid:1)
Fiction power loss.
(cid:1)
Oil flow through bearings and supply
lines.
AVL PEI 9
EXCITE BODY PREPARATION
SUBSTRUCTURING PROCESS FOR FE MODELS
• Finite element models are used to
create flexible bodies for AVL
EXCITE.
• Substructuring is used to eliminate
degrees of freedom to generate a
reduced mass and stiffness matrix.
• Matrices (L) are stored which allow
the retained DOF to be used to
recover stress and displacement
information for the full FE model.
AVL PEI 10