Upfront Durability CAE Analysis for Automotive Sheet Metal Structures

1996 ◽  
Author(s):  
Hari Agrawal ◽  
Al Conle ◽  
Ravi Gopalakrishnan ◽  
Cliff Rivard ◽  
Lokesh Juneja
Keyword(s):  
Sheet Metal ◽  
Metal Structures ◽  
Automotive Sheet ◽  
Cae Analysis

Autonomes Oberflächenschleifen von Aluminium-Anbauteilen/Autonomous grinding of lightweight constructions

2020 ◽  
Vol 110 (07-08) ◽  
pp. 507-510
Author(s):  
Jan-Oliver Brassel ◽  
Severin Hönle ◽  
Jürgen Fleischer ◽  
Hannah Pulli
Keyword(s):  
Sheet Metal ◽  
Metal Surfaces ◽  
Surface Finishing ◽  
Technological Solution ◽  
Metal Structures ◽  
Car Body

Zum Erfüllen der hohen Anforderungen an fehlerfreie Blechteiloberflächen werden häufig manuelle Aufwendungen in die Fertigstellung der Bauteile investiert. Mit Blick auf Produktivität und Wiederholgenauigkeit sollen Teilumfänge der Fertigstellung automatisiert werden. Inhalt dieses Beitrags ist die Konzeption einer Prozesskette zum autonomen Schleifen von Karosseriebauoberflächen sowie die Betrachtung eines Algorithmus zur Berechnung der Bearbeitungsreihenfolge.   Flawless paintwork on car body structures does require defect-free sheet metal surfaces. Therefore, mainly inline and manual refinement efforts are made to surface finishing the single car bodies before painting. Targeting productivity and repeat accuracy can make it necessary to automate certain amounts of this labour-intensive process. This paper presents a technological solution for autonomously grinding sheet metal structures as well as detailing an algorithm for calculating the sequence of steps for autonomous grinding.

scholarly journals Topology Optimization of Automotive sheet metal part using Altair Inspire

2020 ◽  
Vol 5 (3) ◽  
pp. 143-150
Author(s):  
Netsanet Ferede
Keyword(s):  
Topology Optimization ◽  
Sheet Metal ◽  
Optimization Problem ◽  
Optimal Solution ◽  
Sheet Metal Part ◽  
Metal Part ◽  
Solution Quality ◽  
Design Engineers ◽  
Automotive Sheet ◽  
Reduced Costs

In an optimization problem, different candidate solutions are compared with each other, and then the best or optimal solution is obtained which means that solution quality is fundamental. Topology optimization is used at the concept stage of design. It deals with the optimal distribution of material within the structure. Altair Inspire software is the industry's most powerful and easy-to-use Generative Design/Topology Optimization and rapid simulation solution for design engineers. In this paper Topology optimization is applied using Altair inspire to optimize the Sheet metal Angle bracket. Different results are conducted the better and final results are fulfilling the goal of the paper which is minimizing the mass of the sheet metal part by 65.9%  part and Maximizing the stiffness with Better Results of Von- Miss Stress Analysis,  Displacement, and comparison with different load cases.  This can lead to reduced costs, development time, material consumption, and product less weight.

scholarly journals Manufacturing of Innovative Self-supporting Sheet-metal Structures Representing Freeform Surfaces

Procedia CIRP ◽  
2014 ◽  
Vol 18 ◽  
pp. 51-56 ◽  
Author(s):  
D. Bailly ◽  
M. Bambach ◽  
G. Hirt ◽  
T. Pofahl ◽  
R. Herkrath ◽  
...  
Keyword(s):  
Sheet Metal ◽  
Freeform Surfaces ◽  
Metal Structures

A New Approach for Optimization of Sheet Metal Components

2005 ◽  
Vol 6-8 ◽  
pp. 255-262 ◽  
Author(s):  
A. Albers ◽  
H. Weiler ◽  
D. Emmrich ◽  
B. Lauber
Keyword(s):  
Finite Element ◽  
Mathematical Programming ◽  
Sheet Metal ◽  
Optimization Method ◽  
Optimality Criteria ◽  
Body Parts ◽  
Bending Stress ◽  
Element Analysis ◽  
Metal Structures ◽  
Severe Difficulty

Beads are a widespread technology for reinforcing sheet metal structures, because they can be applied without any additional manufacturing effort and without significant weight increase. The two main applications of bead technology are to increase the stiffness for static loading conditions and to reduce the noise and vibrations for dynamic loadings. However, it is difficult to design the bead patterns of sheet metal structures due to the direction-controlled reinforcement effect of the beads. A wrong bead pattern layout can even weaken the properties of the structure. In the past, the designs were predominantly determined empirically or by the use of so called bead catalogues. Recently, different optimization approaches for bead patterns were developed, which are based upon classical mathematical programming optimization algorithms together with automatically generated shape basis vectors. However, these approaches usually provide only vague suggestions for the designs. One of the most severe difficulty with these approaches is to transfer the optimized results into manufacturable designs. Furthermore, another severe difficulty is that the optimization problem is non-convex, which frequently leads the mathematical programming algorithms into a local optima and thus to sub-optimal solutions. The investigations in this article show an optimization method, which within a few iterations leads to bead structures with excellent reinforcement effects using optimality criteria based approach. Generally, the results can be transferred without large effort into a final design. The new optimization method calculates the distribution of the bending stress tensor and the principal bending stresses based upon the results of a finite element analysis. The bead orientations are calculated by the trajectories of the principal bending stress with the largest magnitude. The beads are projected on to the mesh of the component using geometric form functions of the desired bead cross section. A local bead ratio of 50% (defined as average area of the beads in relation to total area of the sheet) is used by the algorithm to determine the maximum moment of inertia. The proposed algorithm is numerical implemented in the optimization system TOSCA and available for being applied with the following finite element solvers: ABAQUS, ANSYS, I-DEAS, NX Nastran, MSC.Nastran, MSC.Marc and PERMAS. The optimization algorithm is successfully applied to static and dynamic real world problems like car body parts, oil pans and exhaust mufflers. In the present work several academic and industrial examples are presented.

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