Dipl.-Ing. Elmar Teipen Dr.-Ing.

Michel Paas
R&A – Global Vehicle Dynamics Ford of Europe – Body Engineering

Dipl.-Ing. Hessel van Dijk Dr.-Ing. Axel Hänschke

Ford of Europe – Body Engineering Ford of Europe – Analytical Prototype

Body Structure & Chassis Optimization

For Improving Driving Maneuvers

2011 European Hyperworks Technology Conference – Bonn

 2011 European Hyperworks Technology Conference - Bonn

Agenda

• Why Body Structure Is Important To Vehicle Dynamics

• What Is The Body Doing During Driving ?
• How To Investigate Structural Performance For VD ?
• Customized Hyperstudy Approach
• MDO Application Examples
• Summary & Next Steps

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Dipl.-Ing. Hessel van Dijk – Body Engineering Europe
 2011 European Hyperworks Technology Conference - Bonn

Why Body Structure Is Important To Vehicle Dynamics

Steering
– Straight Ahead Controllability (On-Center)
 Compliance
 Response: Amount, Linearity, Delay
 Steering Wheel Torque Feedback
 Modulation (Torque vs. Response)
Ride
– Primary Ride
 Control / Comfort
– Secondary Ride
 Shake
 Rolling Feel / Plushness
– Impacts
Solidity / Rigidity / Quality Impression
 Vehicle Dynamics Performance Influenced By Structural Stiffness & Weight

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Dipl.-Ing. Hessel van Dijk – Body Engineering Europe
 2011 European Hyperworks Technology Conference - Bonn

What Is The Body Doing During Driving ?

– Front End Lateral Bending

 On-Center Compliance
 Steering Precision
 Response Delay, Non-Linearity

– Torsion
 Front-to-Rear Balance
 Compliance
 Body Shake, S&R, Rigidity Feel

– Vertical Bending
 Impact Harshness
 Front End Shake, (S&R)

 Trade-Off : Body / Chassis Lightweight  Vehicle Dynamics Performance

Page 4 Nov 8th, 2011 Dipl.-Ing. Elmar Teipen – Global Vehicle Dynamics
Dipl.-Ing. Hessel van Dijk – Body Engineering Europe
 2011 European Hyperworks Technology Conference - Bonn

How To Investigate Structural Performance For VD ?

Local EWS HPC Local EWS

Hypermesh Competitor SW ADAMS/Chassis Hyperworks

Preprocessing MNF-Creation Solving Postprocessing

- ADAMS/Chassis: MBS Pre-Processing (With Vehicle Templates) & Solving

- Embedded FE-Structures Of Body, Subframes, etc.
» Manual Hypermesh Preparation (Superelements, Interface Nodes, ...)
» Modal Reduction With Competitor Software On HPC Supercomputer
» Sequential MNF-Creation: Up To 3 h Per Run / Up To 16 GB mnf To Transfer
» Implementation With Python-Templates (Manually Edited)
- Hyperworks: VD Postprocessing (Based On Maneuver-Dependent Reports)
- Body & Chassis Structural Modifications Based On Individual Results

 Time-Consuming – Manual Interactions – Limited Variations – Not Efficient

Page 5 Nov 8th, 2011 Dipl.-Ing. Elmar Teipen – Global Vehicle Dynamics
Dipl.-Ing. Hessel van Dijk – Body Engineering Europe
 2011 European Hyperworks Technology Conference - Bonn

Customized Hyperstudy Approach

HPC

TCL-Templates Radioss ADAMS/Chassis TCL-Templates

Preprocessing MNF-Creation Solving Postprocessing

Customized
Hyperstudy
Control & PP
- Hyperstudy Customized Integration:
» Selection Of Design Variables (In FE And MBS Templates) User Friendly 
» In-The-Loop Generation / Calculation Of Combined Models Automated Pre+Post 
» Fully Automated DOE Control From Local EWS No Manual Interaction 
» Data-Intensive Work Completely On HPC Supercomputer Reduced File Transfer 
» Semi-Parallel Runs Possible Reduced Run Time 
» Collection Of Final Results (Some kB Per Run) On EWS Reduced Data 
» Optimized License Application Reduced Cost 
 Customized Hyperstudy = Key Enabler For Statistical FE + MBS Analysis on HPC

Page 6 Nov 8th, 2011 Dipl.-Ing. Elmar Teipen – Global Vehicle Dynamics
Dipl.-Ing. Hessel van Dijk – Body Engineering Europe
 2011 European Hyperworks Technology Conference - Bonn

Application Examples: Stepsteer & Ride 4-Poster

Vehicle Dynamics Metrics vs. Sheets
- Steering (Sinesteer, Stepsteer, On-Center)
- Ride (4-Poster, Road 10 Old Part, Blauwe Kei)
- Handling
- Braking

– BIP content within a Trimmed Body + Subframes

– Design Variables: Sheet Thicknesses + ADAMS Bushings
– Generic Responses
» Wheel Loads (nominal, min, max)
» Full Vehicle properties
» Frt Axle Load, Total Weight
– Stepsteer Responses (Time Domain):
» Peak Yaw Rate, Peak LatAcc
» Steady-State LatAcc, Sideslip Angle, ...
– 4-Poster Responses (Frequency Domain):
» 50 PSDs (each 1 – 30 Hz)
(Tpmnts, Seatrails, FrtBending, FulTors, Engine,...)
– Total Time To Complete: 2 Days (1000 Runs)
 Customized HS : Complete In-/Output Matrix

 Vehicle Dynamics Attribute Requirements In Body / Chassis Lightweight MDO

Page 7 Nov 8th, 2011 Dipl.-Ing. Elmar Teipen – Global Vehicle Dynamics
Dipl.-Ing. Hessel van Dijk – Body Engineering Europe
 2011 European Hyperworks Technology Conference - Bonn

MDO Approach
Meta
Modelling

HyperStudy DOE Data Mining CART Analysis

Clustering
Correlations

Optimization

Validation

Page 8 Nov 8th, 2011 Dipl.-Ing. Elmar Teipen – Global Vehicle Dynamics
Dipl.-Ing. Hessel van Dijk – Body Engineering Europe
 2011 European Hyperworks Technology Conference - Bonn

MDO Approach
Meta
Modelling

HyperStudy DOE Data Mining

Optimization

Validation

Page 9 Nov 8th, 2011 Dipl.-Ing. Elmar Teipen – Global Vehicle Dynamics
Dipl.-Ing. Hessel van Dijk – Body Engineering Europe
 2011 European Hyperworks Technology Conference - Bonn

MDO Approach
Meta
Modelling

HyperStudy DOE Data Mining

Optimization

Validation

Page 10 Nov 8th, 2011 Dipl.-Ing. Elmar Teipen – Global Vehicle Dynamics
Dipl.-Ing. Hessel van Dijk – Body Engineering Europe
 2011 European Hyperworks Technology Conference - Bonn

MDO Approach
Meta
Modelling

HyperStudy DOE Data Mining

Optimization

HyperStudy Validation

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Dipl.-Ing. Hessel van Dijk – Body Engineering Europe
 2011 European Hyperworks Technology Conference - Bonn

Application Example: Body Impact @ Full Vehicle Ride

Data-Mining

Zoom: Full Torsion (1 – 30 Hz)

FV Frequency Responses: Ride

Design Variables Body DVs

Page 12 Nov 8th, 2011 Dipl.-Ing. Elmar Teipen – Global Vehicle Dynamics
Dipl.-Ing. Hessel van Dijk – Body Engineering Europe
 2011 European Hyperworks Technology Conference - Bonn

MDO Toolkit Example: Frequency-Dependent Correlations

Data-Mining FV Response

Body DVs

 MDO Toolkit Available To Visualize Structural Effects Against Full Vehicle Metrics

Page 13 Nov 8th, 2011 Dipl.-Ing. Elmar Teipen – Global Vehicle Dynamics
Dipl.-Ing. Hessel van Dijk – Body Engineering Europe
 2011 European Hyperworks Technology Conference - Bonn

MDO Subcase Extension

Meta 1. Total Mass
Modelling &
Optimization
2. Stat. Stiffness

3. Dyn. Stiffness

4. Modes /Tors. Stiffn.

5. EUNCAP ODB

6. Rear Impact

7. LINCAP

8. Meta Models incl. constraint eqs. DVs RVs

+ Vehicle Dynamics / Steering

+ 9. Vehicle Dynamics / Ride

 Additional VD Loadcases To MDO Process = X-Attribute Trade-Off Studies

Page 14 Nov 8th, 2011 Dipl.-Ing. Elmar Teipen – Global Vehicle Dynamics
Dipl.-Ing. Hessel van Dijk – Body Engineering Europe
 2011 European Hyperworks Technology Conference - Bonn

Summary
• Vehicle Dynamics Attribute Significantly Influenced By Structural Stiffness & Weight
• Lightweight Trend: Potentials & Risks For Vehicle Dynamics
• Standard Process Inefficient To Systematically Investigate Trade-Offs
• Customized Hyperstudy Enables X-Attribute MDO Including Vehicle Dynamics
– From Manual Iterations To Automatic Process
– From Local EWS To Supercomputer
– From Competitor Software To Radioss
– From Single Attribute Optimization To X-Attribute MDO

Next Steps
• Process Refinements
• Implementation Of Structural Concepts

Page 15 Nov 8th, 2011 Dipl.-Ing. Elmar Teipen – Global Vehicle Dynamics
Dipl.-Ing. Hessel van Dijk – Body Engineering Europe
 2011 European Hyperworks Technology Conference - Bonn

Contacts
Elmar Teipen Dr. Michel Paas
+49 (0)221 9034526 +49 (0)221 9037755
eteipen@ford.com mpaas@ford.com

Hessel van Dijk Dr. Axel Hänschke

+49 (0)221 9036333 +49 (0)221 9033441
hvandijk@ford.com ahaensch@ford.com

Special Thanks …
• Axel Flick, Altair Office Cologne
• Alexander Koch, Altair Office Cologne
• Thomas Kowalewski, Altair Office Cologne
• Arno Klein, P+Z Engineering
• Matthias Stenkamp, P+Z Engineering

Page 16 Nov 8th, 2011 Dipl.-Ing. Elmar Teipen – Global Vehicle Dynamics
Dipl.-Ing. Hessel van Dijk – Body Engineering Europe
 2011 European Hyperworks Technology Conference - Bonn

Thank you for your attention !

Dipl.-Ing. Elmar Teipen – Global Vehicle Dynamics

Dipl.-Ing. Hessel van Dijk – Body Engineering Europe