Engine-Gasket HPC trial and Suspension NVH analysis using Linear_Perturbation ANSYS Japan Mechanical BU Toru Hiyake © 2014 ANSYS, Inc. October 2, 2014 ANSYS Japan K.K. Proprietary Agenda • Topic 1 : Engine-Gasket Nonlinear Analysis – – – – Legacy Data Import Gasket modeling Bolt Pretension modeling HPC Performance • Topic 2 : Leaf-Spring Suspension Dynamic Analysis – – – – Tire Model Leaf Spring Model Suspension Assy Model Linear Perturbation © 2014 ANSYS, Inc. October 2, 2014 ANSYS Japan K.K. Proprietary Topic 1 : Engine-Gasket Nonlinear Analysis © 2014 ANSYS, Inc. October 2, 2014 ANSYS Japan K.K. Proprietary < Topic 1 : Engine-Gasket Nonlinear Analysis > Legacy Data Import • Data Import in Mechanical using WB tool(External Model) Legacy FE Data (.cdb file) Engine Block(1) ANSYS Mechanical Cylinder Head(x2) © 2014 ANSYS, Inc. October 2, 2014 Gasket(x2) ANSYS Japan K.K. Proprietary Bolt(X16) < Topic 1 : Engine-Gasket Nonlinear Analysis > Legacy Data Import • Engine Block(1) + Cylinder Head(x2) + Gasket(x2) + Bolt(x16) © 2014 ANSYS, Inc. Elements Nodes Total DOF October 2, 2014 : 2,017,780 : 3,379,929 : 10,130,299 ANSYS Japan K.K. Proprietary < Topic 1 : Engine-Gasket Nonlinear Analysis > Gasket Modeling : Element Setting • ANSYS Gasket Elements – Inter192-195 • Change Element Type Gasket – From Solid185 to Inter195 • Solid185 is one order structural element(original element in .cdb file) • Inter195 is one order gasket element – Using Command Object Gasket Mesh Solid185 element © 2014 ANSYS, Inc. October 2, 2014 Inter195 element Command Object ANSYS Japan K.K. Proprietary < Topic 1 : Engine-Gasket Nonlinear Analysis > Gasket Modeling : Material Setting • Gasket Material – The gasket material is usually under compression and is highly nonlinear. – The material also exhibits quite complicated unloading behavior when compression is released. • WB Engineering Data – ANSYS support Gasket material © 2014 ANSYS, Inc. October 2, 2014 Gasket material in WB Engineering Data ANSYS Japan K.K. Proprietary < Topic 1 : Engine-Gasket Nonlinear Analysis > Boundary Conditions : Bolt Model • This boundary condition applies a pretension load to a cylindrical face, to bodies, typically to model a bolt under pretension. – Easy Bolt modeling • In Mechanical , user can set this boundary condition easily. – Pattern copy using object generator © 2014 ANSYS, Inc. October 2, 2014 Bolt Pretension Setting in Mechanical ANSYS Japan K.K. Proprietary < Topic 1 : Engine-Gasket Nonlinear Analysis > Boundary Conditions : Constraints • Direct Node Selection for displacement’s constraint. Boundary Condition Setting in Mechanical © 2014 ANSYS, Inc. October 2, 2014 ANSYS Japan K.K. Proprietary < Topic 1 : Engine-Gasket Nonlinear Analysis > Solver Setting • Analysis Type – Non-Linear Statics • Solver Type Analysis Type Solver Type – Sparse Direct Solver – PCG Iterative Solver • HPC Setting – Parallel Type • SMP(Shared Memory Parallel) • DMP(Distribute Memory Parallel) – Number of Cores • 2,4,8,12 © 2014 ANSYS, Inc. October 2, 2014 HPC Setting Solver Type Parallel Type Sparse SMP DMP PCG SMP Cores 2,4,8,12 DMP Setting Combination ANSYS Japan K.K. Proprietary < Topic 1 : Engine-Gasket Nonlinear Analysis > Hardware Information • DELL T5610 – Type A1 & A2 & A3 • DELL T7600 – Type B CPU Memory HD Drive OS Type A1 8 Core x 2(16 Core) , 2.6GHz 64GB , 1866MHz 3TB , 7200RPM Win7 Type A2 8 Core x2(16 Core) , 2.6GHz 64GB , 1866MHz 256GB , SSD Win7 Type A3 8 Core x2(16 Core) , 2.6GHz 64GB , 1866MHz 420GB, Fusion-io Win7 Type B 6 Core x 2(12 Core) , 2.3GHz 256GB , 1600MHz 2TB , 7200RPM Win8 © 2014 ANSYS, Inc. October 2, 2014 ANSYS Japan K.K. Proprietary < Topic 1 : Engine-Gasket Nonlinear Analysis > Analysis Requirements • Sparse Direct Solver Information 100G Byte!! H/W Solver Type Memory Mode .LN09 Type A Direct Optimal Out-of-Core 95GByte PCG In-Core - Direct In-Core - PCG In-Core - Type B • Nonlinear EQUILIBRIUM ITERATION – Total Number : 8 © 2014 ANSYS, Inc. October 2, 2014 Number of Iteration ANSYS Japan K.K. Proprietary < Topic 1 : Engine-Gasket Nonlinear Analysis > Results Mises Stress Gasket Disp. © 2014 ANSYS, Inc. October 2, 2014 ANSYS Japan K.K. Proprietary < Topic 1 : Engine-Gasket Nonlinear Analysis > Results : Hardware v.s. Solver • Hardware • Solver • Number of Cores : HD , SSD , Fusion-io , Large_MEM : Direct_SMP , Direct_PCG , PCG_SMP , PCG_DMP : 2(Default) 35.0 32.8 32.9 31.7 29.4 30.0 Time (hour) 25.0 18.5 18.3 20.0 16.4 18.3 15.6 15.0 11.4 10.0 10.3 8.5 10.0 7.4 6.8 7.7 5.0 0.0 Direct_SMP Direct_DMP HD © 2014 ANSYS, Inc. October 2, 2014 SSD PCG_SMP Fusion-io PCG_DMP Large_MEM ANSYS Japan K.K. Proprietary < Topic 1 : Engine-Gasket Nonlinear Analysis > Results : Parallel v.s. Solver • Hardware • Solver • Number of Cores 35.0 : SSD : Direct_SMP , Direct_PCG , PCG_SMP , PCG_DMP : 2 , 4 , 8 , 12 32.9 30.0 Time (hour) 25.0 20.0 18.3 17.9 15.0 10.0 11.8 10.3 7.4 7.2 5.5 5.5 5.0 5.6 4.8 10.1 3.4 5.0 3.0 2.5 0.0 2 Cores 4 Cores Direct_SMP © 2014 ANSYS, Inc. October 2, 2014 Direct_DMP 8 Cores PCG_SMP 12 Cores PCG_DMP ANSYS Japan K.K. Proprietary Topic 2 : Leaf-Spring Suspension Dynamic Analysis © 2014 ANSYS, Inc. October 2, 2014 ANSYS Japan K.K. Proprietary < Topic 2 : Leaf-Spring Suspension Dynamic Analysis > Process Flowchart • Workbench Schematic Nonlinear Statics Eigen Value Frequency Response Linear Perturbation © 2014 ANSYS, Inc. October 2, 2014 ANSYS Japan K.K. Proprietary < Topic 2 : Leaf-Spring Suspension Dynamic Analysis > Tire Modeling • Modeling Keyword – – – – Hyper Elastic Material Reinforce Elements Hydrostatic Fluid Pressure Contact Section Tire & Wheel Tire model for NVH Analysis © 2014 ANSYS, Inc. October 2, 2014 Deformation Foot Print ANSYS Japan K.K. Proprietary < Topic 2 : Leaf-Spring Suspension Dynamic Analysis > Leaf Spring Modeling • Modeling Keyword – Large Deformation – Contact – Bushing Plate Contact Front Bush © 2014 ANSYS, Inc. Rear Bush x 2 October 2, 2014 Deformation(Animation) ANSYS Japan K.K. Proprietary < Topic 2 : Leaf-Spring Suspension Dynamic Analysis > Suspension Modeling • Boundary Conditions – Tire Inner Pressure • 0.2MPa – Contact between Tire and Ground • Penalty Method • Friction : 0.2 – Contact between Plates • Augmented Lagrange Method • Friction : 0.2 – Enforced Displacement • Ground Area • Z direction : +40mm Displacement © 2014 ANSYS, Inc. October 2, 2014 ANSYS Japan K.K. Proprietary < Topic 2 : Leaf-Spring Suspension Dynamic Analysis > Suspension Analysis • Non linear Statics – Elapsed Time : 506(s) Non_Linear Iterations Displacement Equivalent Stress Equivalent Elastic Strain(Animation) © 2014 ANSYS, Inc. October 2, 2014 ANSYS Japan K.K. Proprietary < Topic 2 : Leaf-Spring Suspension Dynamic Analysis > Suspension Analysis • Eigen Value Analysis after Static Analysis – Linear Perturbation Process • Initial Stress • Last deformation & Stiffness Mode 2 : 16Hz(Animation) © 2014 ANSYS, Inc. October 2, 2014 Mode 4 : 20Hz(Animation) ANSYS Japan K.K. Proprietary < Topic 2 : Leaf-Spring Suspension Dynamic Analysis > Suspension Analysis • Frequency Response Analysis after Eigenvalue Analysis – Modal FRF Creation Input Point (Under Leaf +Z) Frequency Response Function © 2014 ANSYS, Inc. October 2, 2014 Output Point (Leaf ANSYS Tip +Y) Japan K.K. Proprietary Conclusion • ANSYS HPC performance – ANSYS’s solver performance is continuing to be improved. • SMP/DMP • Direct/Iterative • HPC • ANSYS Non_Linear Staics & Dynamics Analysis – ANSYS has many nonlinear technology. • Gasket • Rubber • Contact • Reinforce • Hydrostatic Fluid • Etc… – Statics & Dynamics combination analysis(Linear perturbation) is very easy using WB. ANSYS Japan K.K. Proprietary © 2014 ANSYS, Inc. October 2, 2014
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