Accelerating the Product Development of a Commercial Vehicle Radiator using Finite Element Analysis

2017 ◽  
Vol 9 (1) ◽  
Author(s):  
P.R. Roy ◽  
V. Hariram ◽  
M. Subramanian
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Product Development ◽  
Commercial Vehicle ◽  
Cooling System ◽  
Experimental Testing ◽  
Engine Oil ◽  
Operating Pressure ◽  
Element Analysis ◽  
Engine Cooling

Emissions such as Nox and CO resulting from the combustion of the diesel engines in the commercial vehicles leads to environmental degradation and ozone layer depletion. Alarming environment trend forces the government institutions to develop and enforce strict emission laws for the next generation transportation vehicles. Stricter emission laws mean higher operating pressure, temperature, reduced weight, tight packaging space, engine downsizing etc. Engine cooling systems are the critical components in the managing the engine cooling requirement of the commercial vehicle. Generally engine cooling system includes radiator, charge air cooler, engine oil cooler etc. Product development of thermal management system using the traditional design process takes more time, resource and money. To solve the complex design problem, numerical technique such as finite element analysis is performed upfront in the product development of the radiator to evaluate the structure behaviour under mechanical loading. In this paper, internal static pressure analysis of a radiator is presented to showcase the benefits of using the finite element technique earlier in the product design phase. Pressure cycle life at a critical joint of the radiator is calculated using strain-life approach. Finite element analysis aids in visualization of the hot spots in the design, comparing different design options with less turnaround time. Experimental testing and prototypes can be reduced. Risk of a product being failed is greatly minimized by performing the numerical simulation.

scholarly journals Finite Element Analysis and Experimental Testing of Stiffness of the Sarafix External Fixator

2015 ◽  
Vol 100 ◽  
pp. 1598-1607 ◽  
Author(s):  
Mešić Elmedin ◽  
Avdić Vahid ◽  
Pervan Nedim ◽  
Repčić Nedžad
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
External Fixator ◽  
Experimental Testing ◽  
Element Analysis

Development of a Product Development Lab Course: Application of Theoretical, FEA and Experimental Techniques

2008 ◽  
Author(s):  
M. Khandaker ◽  
S. Ekwaro-Osire
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Product Development ◽  
Product Design ◽  
Experimental Techniques ◽  
Element Analysis ◽  
Design Problems ◽  
Laboratory Courses ◽  
Senior Design ◽  
Hands On

Finite Element Analysis (FEA) and experimental techniques based laboratory courses are used in the mechanical engineering curriculum to equip students with numerical and experimental abilities to solve design problems. Review of mechanical engineering curricula in US universities found no definite structure for the numerical and experimental based laboratory courses to support the core courses. Also, the authors found that due to lack of knowledge about the application of finite element analysis and lack of collaboration of experimental laboratories in the universities and colleges, students are unable to apply theory, numerical tool and experiment, when it comes to complete product design. To be effective product development engineers, students have to know how to use these engineering tools effectively for various mechanical systems to design a product with perfection. This motivated the authors to develop, teach, and evaluate a laboratory course before the senior design project, where students will have hands on experience with product design. The application of theoretical, numerical and experimental techniques, and their interconnectedness, will also be addressed in this new course. The main three learning objectives of this course were: (1) the ability to apply physical and mathematical models to analyze or design the mechanical systems; (2) the ability to use numerical tools (e.g., FEA) and a fundamental understanding of the limitations of such tools; and (3) the ability to correlate the theoretical knowledge with FEA and experimental findings. Some of the issues observed from the previously taught FEA laboratory related course are: (1) students do not understand how to use FEA tools in practical design problems; (2) students are unable to relate the theory with numerical and experimental result; (3) students do not understand the importance of verification of numerical results; and (4) students with knowledge of a particular analysis background have problems setting up the product design requirements dealing with different analysis systems. To overcome these difficulties, the proposed course will select design problems related to heat, fluid, vibration, and fracture and examine the overall design process including preliminary design, material selection, manufacturing, analysis, and testing. Simulating the complexity of “real world” engineering will prepare students for their senior design projects. The main benefits of this course are: (1) application of theoretical, numerical, and experimental techniques to solve a design problem, and (2) hands on experience with design problems.

Structural analysis of a cross car beam using finite element models

2015 ◽  
Vol 6 (6) ◽  
pp. 759-774
Author(s):  
André F. B. P. Pinto ◽  
S.M.O. Tavares ◽  
José M. A. César de Sá ◽  
P.M.S.T. de Castro
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Modal Analysis ◽  
Mass Production ◽  
Experimental Testing ◽  
Stress Concentrations ◽  
Element Analysis ◽  
Content Type ◽  
Explicit Finite Element ◽  
Simulation Results

Purpose – The purpose of this paper is to use PAM-CRASH, a finite element analysis solver, to assess the performance of a mass production vehicle cross car beam (CCB) under an overlap frontal crash scenario (crashworthiness). Simulation results were reviewed according to what is plausible to register regarding some critical points displacements and, moreover, to identify its stress concentrations zones. Furthermore, it was also computed the CCB modal analysis (noise, vibration and harshness (NVH) assessment) in order to examine if its natural modes are within with the original equipment manufacturer (OEM) design targets. Design/methodology/approach – The available data at the beginning of the present study consisted of the structure CAD file and performance requirements stated by the OEM for NVH. No technical information was available concerning crashworthiness. Taking into account these limitations, it was decided to adapt the requirements for other mass production cars of the same category, as regards dynamic loading. A dynamic explicit code finite element analysis was performed throughout the CCB structure simulating the 120e−3 s crash event. For the modal analysis, there were some necessary modifications to the explicit finite element model in order to perform the analysis in implicit code. In addition, the car body in white stiffness was assigned at the boundaries. These stiffness values are withdrawn from the points where the CCB is attached to the car body’s sheet metal components. Findings – Although the unavailability of published results for this particular CCB model prevents a comparison of the present results, the trends and order of magnitude of the crash simulation results are within the expectations for this type of product. Concerning modal analysis, the steering column first natural frequency has a percent deviation from the design lower bound value of 5.09 percent when local body stiffness is considered and of 1.94 percent with fixed boundary conditions. The other requirement of the NVH assessment regarding a 5 Hz minimum interval between first vehicle CCB mode and the first mode of the steering column was indeed achieved with both boundary configurations. Originality/value – This study is a further confirmation of the interest of numerical modeling as a first step before actual experimental testing, saving time and money in an automotive industry that has seen an enormous increase of the demand for new car models in the last decade.

Analysis of Contact Pressure Distribution on 3-Bolt Self-Energized Connector Seals

2009 ◽  
Author(s):  
Rajeev Madazhy ◽  
Sheril Mathews ◽  
Erik Howard
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Pressure Distribution ◽  
Contact Pressure ◽  
Maximum Pressure ◽  
Operating Pressure ◽  
Seal Ring ◽  
Contact Pressure Distribution ◽  
Element Analysis ◽  
Novel Design

A novel design using 3 bolts for a self-energized seal connector is proposed for quick assembly applications. Contact pressure distribution on the surface of the seal ring during initial bolt-up and subsequent operating pressure is analyzed for 3″ and 10″ connectors using Finite Element Analysis. FEA is performed on a 3″ and 10″ ANSI RF flange assembly and contact pressure distribution on the RF gasket is compared with the tapered seal ring assemblies. Hydrostatic tests are carried out for the tapered seal and ANSI bolted connectors to evaluate maximum pressure at which leak occurs for both size assemblies.

scholarly journals Finite element analysis of dovetail joint made with the use of CNC technology

2010 ◽  
Vol 58 (5) ◽  
pp. 321-328 ◽  
Author(s):  
Václav Sebera ◽  
Milan Šimek
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Numerical Models ◽  
Experimental Testing ◽  
Joint Stiffness ◽  
Bending Moment ◽  
Parametric Models ◽  
Cnc Machine ◽  
Element Analysis ◽  
Bending Load

The objective of the paper is the parametrization and the finite element analysis of mechanical pro­per­ties of a through dovetail joint made with the use of a specific procedure by a 3-axis CNC machine. This corner joint was used for the simulation of the bending load of the joint in the angle plane – by compression, i.e. by pressing the joint together. The deformation fields, the stress distribution, the stiffness and the bending moment of the joints were evaluated. The finite element system ANSYS was used to create two parametric numerical models of the joint. The first one represents an ideal­ly stiff joint – both joint parts have been glued together. The second model includes the contact between the joined parts. This numerical model was used to monitor the response of the joint stiffness to the change of the static friction coefficient. The results of both models were compared both with each other and with similar analyses conducted within the research into ready-to-assemble furniture joints. The results can be employed in the designing of more complex furniture products with higher demands concerning stiffness characteristics, such as furniture for sitting. However, this assumption depends on the correction of the created parametric models by experimental testing.

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