Read Session05_Faurecia_Monteagudo text version

Size Optimization process of an Exhaust System

Mauricio Monteagudo G.

R&D Exhaust Durability Manager

Faurecia R&D Center, France.

2nd European Hyperworks Technology Conference 2008 Strasbourg, France.

Content Introducing Faurecia Aim Virtual Durability Product Development

Brief review= Low Frequency Analysis ?! Problem description

Size Optimization Summary & Conclusions

2nd Hyperworks Technology Conference Strasbourg, France. Property of Faurecia - duplication prohibited

2

2

Introducing Faurecia

Faurecia is an expert in 6 major modules

Acoustic package n° in Europe 3 Door panel / Modules n° in Europe 1 n° worldwide 1

Exhaust system n° in Europe 1 n° worldwide 2

Instrument panel / Cockpit n° in Europe 1 n° worldwide 1

Seating n° in Europe 2 n° worldwide 3

Front end n° in Europe 1 n° worldwide 2

4

International ESPG footprint

EUROPE 9 Production plants 10 JIT 1 R&D center 3 D&D centers USA Korea China

NORTH AMERICA 6 Production plants 3 JIT 1 D&D center Mexico

ASIA 5 Plants 1 Customer office 2 D&D centers Japan

Plants R&D Center D&D Center Customer Office

Brazil Argentina

ROW 3 Plants 1 JIT South Africa

www.faurecia.com

5

Aim

Aim

Applying Size Optimization (modification of properties) approach to:

NVH

Decrease Hanger Forces Early selection of decoupling elements dynamic characteristics

Durability

Bending Moments at the I/O volumes Stress values vs. worst resonant frequencies Lightweight if loads are lower thanks to the more efficient decoupling values.

Time

Global virtual durability development to optimize the dynamic behavior of Exhaust Systems.

7

2nd Hyperworks Technology Conference Strasbourg, France. Property of Faurecia - duplication prohibited

7

Virtual Durability Development

8

Overview of Exhaust System

Hot End

Emission control

Cold End

Acoustic

Structural integrity

Durability

2nd Hyperworks Technology Conference Strasbourg, France. Property of Faurecia - duplication prohibited

9

9

Virtual Durability Development

SOR

Vehicle Level

Complete Exhaust Validation

System Level Low Frequency

[Engine load] ~ 20­250 Hz

Subsystem Level

I

Engine Bench Electrodynamics Bench

I

Very Low Frequency

[Road & Engine loads] ~ 0-20 Hz

Component Level

I

Exhaust System Key Life Test

Fatigue Life Design

2nd Hyperworks Technology Conference Strasbourg, France. Property of Faurecia - duplication prohibited

I

Uni (Bi)-axial Force Loading Bench 10

10

Brief review = Low Frequency Analysis

Engine Excitation Load

40µ Culasse Culasse Culasse Culasse X- Order: 1.5 X- Order: 3.0 X- Order: 1.5 X- Order: 3.0 RMS15-Jul-08 RMS15-Jul-08 RMS22-Jul-08 RMS22-Jul-08 09:07:53 09:07:53 22:08:37 22:08:37 30µ Amplitude m

To evaluate the reacting forces at each hanging point that could induce Structure Borne Noise in the Vehicle or NVH To compute the bending moments, at inlet/outlet of volumes. To evaluate the stress map for each measuring points for worst resonant Frequencies tuning the structural experimental damping Hanger Force Flex Coupling

CS

20µ

10µ

0 1k 2k 3k 4k Rotation speed - rpm 5k 6k 6.5k

K

Static& Dynamic

*

Kx Ky Kz Kx Ky Kz

Bending moment at the I/O of volumes

Isolators

K

Static& Dynamic*

Kx Ky Kz

CS

Worst Resonant Frequencies

11

2nd Hyperworks Technology Conference Strasbourg, France. Property of Faurecia - duplication prohibited

11

Problem description

Today

know-how to isolate engine vibrations using standard decoupling elements (Flex coupling & Isolators)

Challenge

To know the most accurate linear dynamic stiffness values by optimization loops to evaluate the reacting forces at each hanging point that could induce NVH

RF3 Z direction

60

RF3 Z direction

16 14

50

12

40 AVD Force (N)

10 Force (N) 8 6 4

AVD AVG ARD ARG CDC

AVG 30 ARD ARG CDC 20

10

2 0

30 50 70 90 Frequency (Hz) 110 130 150

0

30

50

70

90 Frequency (Hz)

110

130

150

Without Flex

2nd Hyperworks Technology Conference Strasbourg, France. Property of Faurecia - duplication prohibited

With Flex

12

12

Size Optimization

13

Size Optimization

Target

To minimize hanger force in each direction < 10 N To keep lower stress map and bending moments < 100 N*m

Potential design parameters

Flex Coupling: Kx, Ky, Kz, Hx, Hy, Hz (6) Isolators: Kx, Ky, Kz (2x3 = 6)

K

Static& Dynamic*

Kx Ky Kz Kx Ky Kz

CS

K

Static& Dynamic*

Kx Ky Kz

CS

Inputs

Engine behavior load (FRF) for critical Eigen values Temperature map loaded Damping values are fixed according experimental tuning 14 Decoupling elements dynamic characteristics data base

2nd Hyperworks Technology Conference Strasbourg, France. Property of Faurecia - duplication prohibited

14

Size Optimization

1st Loop

Rear isolator Front isolator

Flex

Kx (N/mm) Ky (N/mm) Kz (N/mm) Kx (Nmm/rad) Ky (Nmm/rad) K z (Nmm/rad)

Lower bound 500 100 000 100 000 75 e+05 400 000 400 000

Initial values 1000 200 000 200 000 15e+06 800 000 800 000

Upper bound 1500 300 000 300 000 225e+05 1.2e+06 1.2e+06

Optimized values 500 300 000 100 000 225e+05 81 362 1.2e+06

Front Isolator

Kx (N/mm) Ky (N/mm) Kz (N/mm)

Lower bound 4.8 4.8 24

Initial values 16 16 40

Upper bound 17 17 41

Optimized values 17 17 41

Rear Isolator

Kx (N/mm) Ky (N/mm) Kz (N/mm)

2.4 2.4 12

8 8 20

14 14 28

14 14 12 15

2nd Hyperworks Technology Conference Strasbourg, France. Property of Faurecia - duplication prohibited

15

Size Optimization

16

2nd Hyperworks Technology Conference Strasbourg, France. Property of Faurecia - duplication prohibited

16

Size Optimization

2nd Loop

Rear isolator Front isolator

Flex

Kx (N/mm) Ky (N/mm) Kz (N/mm) Kx (Nmm/rad) Ky (Nmm/rad) K z (Nmm/rad)

Lower bound 100 20 000 20 000 1.5e+06 80 000 80 000

Initial values 1000 200 000 200 000 15e+06 800 000 800 000

Upper bound 2000 400 000 400 000 30e+06 1.6e+06 1.6e+06

Optimized values 351 400 000 30 585 30e+06 749 512 1.6e+06

Front Isolator

Kx (N/mm) Ky (N/mm) Kz (N/mm)

Lower bound 1.6 1.6 4

Initial values 16 16 40

Upper bound 32 32 80

Optimized values 32 5.5 10

Rear Isolator

Kx (N/mm) Ky (N/mm) Kz (N/mm)

0.8 0.8 2

8 8 20

16 16 40

14 9 2 17

2nd Hyperworks Technology Conference Strasbourg, France. Property of Faurecia - duplication prohibited

17

Size Optimization

18

2nd Hyperworks Technology Conference Strasbourg, France. Property of Faurecia - duplication prohibited

18

Size Optimization

Max Von Misses stress

With initial values

Frequency (Hz) Von Mises stress (MPa)

34 4.8 43 6.9 61 5.6 69.5 5.3 109 10.7 116. 5 1.5 141.5 5.9

With optimized values (1st loop)

Frequency (Hz) Von Mises stress (MPa)

35 2.8 43 18.2 61 3.7 68.5 7.1 110 14.5 116. 5 7.3 134 2.9

19

2nd Hyperworks Technology Conference Strasbourg, France. Property of Faurecia - duplication prohibited

19

Size Optimization

Typical dynamic characteristics values (example)

140 120 100 N/mm 80 60 40 20 0

0 50 100 150 200 250 300 350 400

+ Z Direction

Hz

20

2nd Hyperworks Technology Conference Strasbourg, France. Property of Faurecia - duplication prohibited

20

Summary & Conclusions

Summary & Conclusions

Size Optimization approach was developed for Exhaust Systems in Low frequency domain. An case study was presented here and proved the Size Optimization approach can predict Flex coupling and Isolators dynamic characteristics in the earliest virtual development stage. The compromise of decreasing hanger forces and keeping lower stress values and bending moments is possible. The predicted results were correlated reasonably with observed results from Faurecia decoupling elements data base assuring the steadiness of results. Size Optimization is able to predict dynamic performance of exhaust which 22 enables to avoid the treat of presumptive dynamic stiffness values in order to reach the design targets applying advance mathematical tools like OptiStruct.

2nd Hyperworks Technology Conference Strasbourg, France. Property of Faurecia - duplication prohibited

22

Thank you for your attention.

References

Mauricio Monteagudo Galindo, Science and Technology Designing Exhaust Systems. SAE 2003 Noise & Vibration Conference, 2003-01-1656. M. Monteagudo, J. Clavier, T. Lauwagie, J. Strobbe, E. Dascotte, Optimization of the Dynamic Response of a Complete Exhaust System, ISMA2008 OptiStruct, User's Manual, version 8.

2nd Hyperworks Technology Conference Strasbourg, France. Property of Faurecia - duplication prohibited

Contact

Mauricio Monteagudo Galindo R&D Exhaust Durability Manager Faurecia R&D / France. Tel: +(33) 3 81 99 25 63 [email protected]

23

23

Information

Session05_Faurecia_Monteagudo

25 pages

Report File (DMCA)

Our content is added by our users. We aim to remove reported files within 1 working day. Please use this link to notify us:

Report this file as copyright or inappropriate

1192401


You might also be interested in

BETA
Session05_Faurecia_Monteagudo