ANSYS_Automotive_Comprehensive_Solutions

©2011ANSYS,Inc.June30,20141ANSYSAutomotiveComprehensiveSolutions:BrakeDesignAshokKhondgeLeadTechnologySpecialistANSYSInc.©2011ANSYS,Inc.June30,20142•AutomotiveIndustryTrends&Implications•ANSYSComprehensiveSolutions•TheAutomotiveBrakeIndustry:BusinessDrivers&Challenges•ANSYSBrakeSystemSolutions1.BrakeSystemInstability(BrakeSqueal)2.BrakeThermal&Cooling•SummaryAgenda©2011ANSYS,Inc.June30,20143KeyVehicleSystemsareUndergoingDrasticChangestoreducethecarbonfootprintsReduceCarbonFootprintEnergyRecoveryPowertrainLightweightDesignRoadResistanceAerodynamicsHEV/EVThermalManagementEnergy©2011ANSYS,Inc.June30,20144WarrantyExpensesAreAKeyOngoingConcernForAuto-makersAndSuppliersWarrantyReductionCatchingdesignfaultsearlyBrakeSquealEarlyIntroductionofquality&reliabilitypredictionSystemInsightsintosystemLevelInterdependenciesDesignOptimization©2011ANSYS,Inc.June30,20145ANSYSEnablesYouToAccomplishYourInitiativesByImprovingYourProductDevelopmentProcessesWithCross-IndustryComprehensiveSolutionsYourCriticalSuccessFactors(CSFs)ReductionofVehicleWeightReductionofBatteryCostandIncreasedLifeReductionofRareEarthContentImprovedEngineCombustionEfficiencyFasterInnovationCycleforConsumerFeaturesEMI-EMCRegulationComplianceUpstreamPreventiveQualityControlANSYS’sCross-IndustryComprehensiveSolutionsAdvancedMaterialSystemsDesignRobustElectronicSystemsDesignFluid-MechanicalSystemsDesignElectricMachineandDriveSystemsDesignFluid-ThermalSystemsDesignKeyBusinessInitiatives(KBIs)ImproveFuelEconomyandEmissionsDevelopHybridandElectricVehiclesManageComplexityofElectronicsandEmbeddedSystemsImplementanEarlyQualityandReliabilityPredictionSystem©2011ANSYS,Inc.June30,20146ANSYS’sAutomotiveComprehensiveSolutionsareDerivedfromCross-IndustryKnowledgeBringBest-In-ClassInsightstoSolveYourProductDevelopmentChallengesANSYS’sCross-IndustryComprehensiveSolutionsAdvancedMaterialsSystemsDesignRobustElectronicSystemsDesignFluid-MechanicalSystemsDesignElectricMachineandDriveSystemsDesignFluid-ThermalSystemsDesignANSYS’sAUTOMOTIVEComprehensiveSolutionsStrongandDurableCompositesDesignSafe,Long-LastingBatteryDesignUpfrontAero-ThermalOptimizationRobust,EfficientTractionMotorDesignEfficientandDurableEngineCoolingSystemDesign©2011ANSYS,Inc.June30,20147TheAutomotiveBrakeIndustryBusinessDrivers•WarrantyReduction&Customersatisfaction•Increasenumberofplatforms•InnovationBrakeSystemDesignChallenges•Virtualdesignofcostseffective,quietbrakingsystemsundereverincreasingtimepressure•SystemComplexity•PhysicsComplexity•NumberofPlatforms•Designersproductivity•In-syncmodelswithproduction•OEMandsupplychaininteractionCourtesyof:AutomotiveCompany©2011ANSYS,Inc.June30,20148BrakeSystemSolutionsSolutions•ANSYSbrakeapplicationexperience•ANSYSsystemmodeling,Mechanical,CFDandelectromagnetics•MultiphysicsparametricoptimizationwithgeometryInterfacestoCAD•AdvancedcapabilitiestomodelbrakeinstabilityBusinessBenefits•50%fasterinproblemsetup•45%fasterinprojectcompletion•NewproductinnovationCourtesyof:AutomotiveCompany©2011ANSYS,Inc.June30,20149SystemModelingHydraulicControlElectromagneticDynamicloadingStructuralThermalstressNon-linearstaticsDynamics(NVH)DurabilityWearMBDCrashElectromagneticLowandhighfrequencyActuators,sensorsThermalSteadyandTransientFEAand/orCFDBrakeSystemDesign©2011ANSYS,Inc.June30,201410BrakeInstabilityAnalysis•Brakediskdevelopfrictioninducedoscillationswhichareheardas“brakesqueal”.•Brakenoisehasbeenachallengingissueforautomotiveindustry.•BrakeNoiseCategoriesLowfrequencynoise(100-1000Hz)–GroanandMoannoiseLowfrequencysqueal(1000–7000Hz)–Couplingofoutofplanemodesofrotorwithbendingmodesofpads.Highfrequencysqueal(8000-16000Hz)–Couplingofinplanemodesofrotorwithbendingmodesofpads.Courtesyof:AutomotiveCompany©2011ANSYS,Inc.June30,201411ANSYSBrakeSqueal:Accuracy•Experimentalvalidationfornumericalanalysis;about4%error(Ref:2013ESSS&ANSYSUGMandSAEPaper2013-36-0030)PredictedUnstableModePredictedFrequencySquealingFrequency(Experimental)%Error5310795Hz10350Hz4.29%6913165Hz12875Hz2.25%6075901051200200040006000800010000120001400016000SoundPressureLevel(dB[A])Frequency(Hz)SoundPressureLevelvs.FrequencyforallStopsAboveThreshold(70dB)ForwardReverseDragDecelFig.Brakeassemblyofatestonthedynamometermode53©2011ANSYS,Inc.June30,201412TraditionalandPresentSimulationapproachesTraditionalApproachNewANSYSWBApproachPrestressanalysishastobelinearPrestressanalysiscanbenon-linear,modalanalysisiscarriedoutusinglinearperturbationmethod.Discrete2node(springs)elementsareusedtoprovideFrictionstiffness(MATRIX27)FrictionstiffnessiscalculatedfromthecontactdefinitionRequiresmatchingnodesattheslidinginterfaceDoesnotrequirematchingmeshbetweenrotorandpadsRotor-padinterfaceisnotconsistentConsistentrotor-padinterfaceImpracticalforparametricstudiesBestsuitedforparametricstudiesTediousandtimeconsumingEasySetup©2011ANSYS,Inc.June30,201413Threedifferentmethods•FullNonlinearPerturbedModalAnalysis•PartialNonlinearPerturbedModalAnalysis•LinearNon-prestressedModalAnalysisANSYSApproachProjectSchematic©2011ANSYS,Inc.June30,201414Howtouse