door slam simulation for durability analysis with ... · 2nd european hyperworks technology...

2nd European HyperWorks Technology Conference Strasbourg September 30th –October 1st, 2008

TOYOTA AUTO BODY CO.,LTD.Computer Aided Engineering Div.

○ Takeshi Inoue

September 30th –October 1st .2008

Hiroaki Hoshino

Altair Engineering

Door slam simulation for durability analysis withMultibody Dynamics

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Toyota Auto Body is developing andproducing minivans, SUVs and commercialvehicles as a main Toyota affiliate.

・ALPHARD・NOAH/ VOXY・ESTIMA・ESTIMA HYBRID・IPSUM

・PRIUS

・LAND CRUISER 200・LEXUS LX570・LAND CRUISER 70 PICKUP・LAND CRUISER 70 HARDTOP

・HIACE・REGIUSACE・HIACE (for Europe)・COASTER

・Freezer vehicle・Container van・Load labor-saving vehicle・COASTER SCHOOL BUS・HIACE FREEZER

・Wheelchair-customized Vehicle・Transport of People with Reduced Mobility・Wheelchair-customized vehicle(Ramp-

type）・Vehicle with lift seat for rear passenger・Vehicle with lift seat for front passenger・Automatic Rotating and Sliding Passenger

Seat・Barrier free device

・Electric Vehicle Everyday・Urtra Small Electric Vehicle COMS

Products Line-up

TOYOTA AUTO BODY CO.,LTD.Company Profile

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1. Doors of car

2. Background and Objective

3. Door slam simulation3-1. Simulation flow

3-2. Simulation conditions

3-3. Results validation

3-4. Accuracy improvement

4. Future plan –Application to other door types and durability evaluation

5. Conclusion

Door slam simulation for durabilityanalysis with Multibody Dynamics

Contents

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1. Doors of car







5. Conclusion


Contents

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Hood Side door

Sliding door Trunk

Hatch

Tail Gate

Doors should fulfill the required functions fully indoor open-close operations during whole car life.

Doors of car

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1. Doors of car







5. Conclusion


Contents

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Open-close durabilitywith prototype

- Input(Lock, Cushion rubber)- Crack information

Test

Static analysis

CAE

Proposal of designmodification

Unable to evaluate by CAEwithout information from test

Issues •Need the test of original vehicle

•Unable to change design for different input condition

Much cost and time

Need re-test !

Door open-close durability evaluation –conventional approach

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Stress analysisLife evaluation

Structure modification

Geometry & Property

•Complete evaluation by CAE without real product

•Able to respond to design modifications

⇒

In-housesystem

Door behavior simulation

Close-open durability testTest

Objective

Load time history

Reduction of number of test reducesdesign cost and development period

Design Dynamic analysisCAE

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1. Doors of car







5. Conclusion


Contents

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Estimate the load acting on door during door closing

Consider the non-linearity of displacement-load characteristics oflock, seal and rubber

Consider the lap clearance on sealing parts and rubbers

Car body is assumed as rigid

Consider the door flexibility

Study the simulation on the front door as initial step

Clear the locations and requirements for design modification

Apply to other types of door

Study of Door behavior simulation

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1. Doors of car







5. Conclusion


Contents

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CAD data

**.h3d (Flexible body)

**.mrf (Plot) **.h3d (Animation)

MotionSolveAnalysis

HyperMesh

FEM model creation

MotionView

Build MBD modelDefine simulation conditions

HyperGraph

Load time history

Radioss/Analysis

Modal properties

Deformation

HyperView

Flow of door slam simulation

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1. Doors of car







5. Conclusion


Contents

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Lock positionClose velocity definition

Cushion rubber loadproperty

Lock load property

Whether-strip loadproperty

Revolutejoints

Load = Stiffness + Damping

F = + Damping coefficient * velocity

Load locationsWeather-stripCushion rubberLockdisp

Load

F = Kx + Cv

Displacement

Load

Load property

Model conditions

Assembly flexible body

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1. Doors of car







5. Conclusion


Contents

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Deformation（Scale 30） Load time history

Simulation results

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time

load

TestOriginal

Load at door lock

time

load

TestOriginal

Load at upper rubber

time

load

TestOriginal

Load at lower rubber

time

acceleratio

n

TestOriginal

Acceleration at door lockLoad at door lock



Measuring positions

smaller level after initial peak

larger lock damping

smaller cushion rubber damping

larger load at first & second peaksNeed to tune the damping of lockand cushion rubber respectively

Original model validationAccelerationat door lock

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1. Doors of car







5. Conclusion


Contents

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Comparison withtest results

End

Yes

HyperGraph

Geometry

HyperMesh

Radioss / Analysis

**.h3d (Flexible Body)

MotionSolveAnalysis

MotionView

Build MBD modelDefine simulation conditions

Input data

HyperStudy

No

System Identification

Flow of model accuracy improvement

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{parameter(Lock,"CL", 1,10, 100)}{parameter(Srubber,"CS", 2, 20, 200)}{parameter(WStrip,"CW", 1, 10, 100)}

<Force_Vector_OneBodyid = "30101"type = "ForceOnly"marker_id = "30102021"ref_marker_id = "30101010"fx_expression = "0"fy_expression = "VARVAL(30100100)+{Lock, %8.5f}*VY(30101280,30102020)"fz_expression = "0"

/><Force_Vector_OneBody

id = "30103"type = "ForceOnly"marker_id = "30102051"ref_marker_id = "30101010"fx_expression = "0"fy_expression = "VARVAL(30100300)+{Srubber, %8.5f}*VY(30101310,30102050)"fz_expression = "0"

/><Force_Vector_OneBody

id = "30105"type = "ForceOnly"marker_id = "30102071"ref_marker_id = "30101010"fx_expression = "0"fy_expression = "VARVAL(30100500)+{WStrip, %8.5f}*VY(30101330,30102070)"fz_expression = "0"

/>

Lock

Stopper rubber

Weather strip

< Design variables >

Damping optimization (HyperStudy)

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< Objective >

sqrt((max({v_1})-f0)^2+(min({v_1})+f1)^2+(max({v_2})-f2)^2+(max({v_3})-f3)^2)

Minimize SQRT( a2 + b2 + c2 + d2 )

Load at door lock Load at upper rubber Load at lower rubber

Load Time

v_1 v_2 v_3

Time Time

a

b

cd

f0

f1

f2f3

Damping optimization (HyperStudy)

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Load at door lock

Load at door lock



Measuring positions

Accelerationat door lock

Load at upper rubberLoad at lower rubber

Acceleration at door lockModified model validation

time

load

TestOriginalModify

time

acceleration

TestOriginalModify

time

load

TestOriginalModify

time

load

test

Original

Modify

Similar to test results

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Confirmed the good correlation in the front doors ofother car types using identified damping.

May need to identify the damping factors for the front doors with much differentstructure and mechanism.

t ime

load

Te stSedan A

t ime

load

TestSedan A

time

load

t estSedan A

tim e

load

TestMin i Van B

time

laod

Te atM in i Van B

time

load

Te stMin i Van B

Time

Load

Test

SUV C

Time

Loa

d

Te st

SUV C

Time

Load

Test

SUV C

Load at door lock Load at upper rubber Load at lower rubber

Sedan A

Mini Van B

SUV C

Validation of identified damping

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1. Doors of car







5. Conclusion


Contents

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Weather-stripload

Revolute joints

Condition the closing speed

Cushion rubber load

Lock load

Cushion rubberload

Damper load

Define flexibledoor

Other type of door application [Hatch]


F = + Damp. coef.* velo

Load locationsWeather-stripCushion rubberLockDamperdisp

LoadF = Kx + Cv

Displacement

Load

Load property

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Simulation results on hatch

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Weather-strip load

Condition theclosing speed

Cushion rubber load

Flexible car body

Rail : point-curve constraint

Lock load

Flexible door

Cushion rubberload

Lock load

Other type of door application [Sliding door]

Load locationsWeather-stripCushion rubberLock


F = + Damp. coef.* velodisp

LoadF = Kx + Cv

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Simulation results on sliding door

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Geometry

HyperMesh

**.h3d (Flexible body)

MotionView(Build MBD model)

Radioss / Analysis

HyperStudyMotionSolve

Future plan –Durability evaluation

Validation of stress time history

time

strain

FEMFATIn-house tool or

Eigen vectorsModal composite

Fatigue analysis

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1. Doors of car







5. Conclusion


Contents

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Developed the process of front door slam simulation in HyperWorks

Established the Multibody Dynamics technology for door slamsimulation

Identified the damping factors in comparing with the test results

Confirmed the ability to simulate the door slam test in HyperWorks

Future plans

Apply this technology to other types of door

Door durability evaluation

Using the developed process for product design from now

Conclusion

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Thank you for your attention!

door slam simulation for durability analysis with ... · 2nd european hyperworks technology...

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