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OTEKON’14
7. Otomotiv Teknolojileri Kongresi
26 - 27 Mayıs 2014, BURSA
CAE INTEGRATED DESIGN OF FEAD BRACKET USING
ABAQUS FOR CATIA (AFC)
Osman Emre Arslan, Ömer Kaya
Ford Otosan AŞ, Motor ve Güç Aktarma Organları Mühendisliği, Gebze / Kocaeli
.
SUMMARY:
CAE integrated design is a great tool that provides the benefit of combining design and analysis processes on the
same platform using Abaqus for CATIA. It allows designer to conduct design and analysis at the same interface quickly
and efficiently.
The importance of using this methodology is to close the bridge between CAD designer and CAE analyst. AFC has
proved to be a very effective pre-processor that speeds up the design process. It is clearly seen that the benefit of
including CAE in the early stages of design leads to a fully optimized models with considerable time, head and cost
savings.
Keywords: FEAD system, non-linear analysis, Durability, Abaqus for CATIA,
models in terms of durability simultaneously and drive
further design iterations.
1. INTRODUCTION
CAE integrated design process is a vital tool that
establishes quick and responsive design. The traditional
method allows design and analysis iteration processes are
done by different teams. The result is inefficient time
consumption and head workload. In the new methodology
CAD designer/engineer can combine design iterations and
respective analysis by AFC tool. In addition to this CAE
model can be updated easily. So, designer generates
several models and related analysis iterations just working
on the CATIA environment. Only sign-off or guidance
step is required from CAE team. By implementing this
method, about 60-70% time saving and head workload
reduction have gained when compared to traditional
method.
The new methodology is examined by case study of
FEAD bracket design of a heavy duty engine. Heavy duty
engines are subjected to extreme loading conditions and
works in difficult physical environments. Each engine
component must be designed and analyzed accurately.
FEAD system is subjected to engine vibrations and
random road loads. Therefore, FEAD bracket structural
analysis is conducted to investigate the effects of those
mechanical loading in order to avoid failure. By using this
methodology, an iterative optimization of the part is
undertaken. CAE model is updated automatically with
geometry changes. That allows designer to check the
Figure 1.
Comparison of
Integrated Process
1
Traditional and CAE
1. CASE STUDY
2.1. CAE Model
FEAD bracket structural model includes FEAD
bracket, cylinder block, idler pulley, bracket and pulley
bolts.
FEAD bracket is assembled to cylinder block with
2xM8 bolts and 1xM10 bolt is used to assemble the idler
pulley to the bracket. Since cylinder block is assumed to
be very rigid, only a small part of the block is included in
the model. All parts have second order tetra elements.
Components and corresponding materials are listed
below. (Table1)
Figure 3. FEAD Bracket AFC Contact Definitions.
Part
M8 Bolt - Bracket
M8 Bolt - Block
M10 - Pulley
M10 - Bracket
Bracket - Block
Pulley - bracket
Table 1. AFC CAE Model Material Details.
Contact Type
Contact Pair
Bolt Tightening
Contact Pair
Bolt Tightening
Contact Pair
Contact Pair
Friction
Friction-Small Sliding
Friction-Small Sliding
Friction-Small Sliding
Friction-Small Sliding
Table 2. AFC Contact Details.
2.3. Boundary Conditions & Loads
FEAD system is directly driven by the crankshaft
pulley with help of a flexible V-belt. Bracket carries one
groove-type pulley and has 2-bolt fixation to the cylinder
block. Cylinder block section is constrained in all
directions. In the first step, maximum pretension load are
assigned to two M8 bolts and one M10 bolt. Then bolts
are fixed in next step. In the second step, V-belt load are
also applied to idler pulley. In the final step, all
components are subjected to gravity loading to simulate
the impact loading. Magnitude of the gravity load is
determined according to FO experience. 3-different
design iterations are undertaken with the same model.
Figure 2. FEAD bracket AFC Mesh Model.
2.2. Contact Definition
# Step
1
2
3
Several contact interaction are defined in the model. A
regular contact with small sliding is used. Bolts are
modeled as solid elements with PRE-TENSION surfaces.
Contact definitions are shown in Fig. 2 and Table 2.
Table 3. AFC Analysis Steps.
2
Loading Conditions
Max Bolt Load
Fix Bolts
FEAD Belt Loading
Gravity Impact Loading
3.
DESIGN ITERATIONS & RESULTS
- Iteration-3:
Final iteration shows the optimum rib geometry which is
effectively distribute force to all ribs and side walls. So,
this stress levels is acceptable.
Design iterations are driven by analysis results. It is
proved that bracket rib geometry changes stress levels
significantly. The third design iteration has durable
structure enough to freeze the design. Each design
iteration and CAE model updates take only few minutes
to construct a new analysis case. That helps designer to
try out many models in a short period of time.
- Iteration-1:
The critical areas are shown by red circles. The middle rib
geometry is ineffective. Therefore, bottom and top ribs
are critically affected.
Figure 6. FEAD bracket Iteration-3 Result.
4. CONCLUSION
CAE integrated design is a great tool that provides the
benefit of combining design and analysis processes on the
same platform using Abaqus for CATIA. It allows the
designer to conduct design and analysis at the same
interface quickly and efficiently.
Figure 4. FEAD Bracket Iteration-1 Result.
The importance of using this methodology is to close the
bridge between CAD designer and CAE analyst. AFC has
proved to be a very effective pre-processor that speeds up
the design process. It is clearly seen that the benefit of
including CAE in the early stages of design leads to a
fully optimized model with considerable time and cost
savings.
- Iteration-2:
Bracket strength is improved with the change of middle
rib geometry . However, there were still critical areas.
The real-time boundary conditions are included and
working environment is simulated in case study. As a
results, optimized bracket design was executed with just
consuming 1/3 effort of traditional approach.
REFERENCES
1.
2.
3.
Figure 5. FEAD bracket Iteration-2 Result.
3
Geometry Translator User’s Guide, 2006, CATIA
V5 to ABAQUS/CAE
Abaqus for Catia V5 Manual, Realistic Simulation
Inside Catia V5
Abaqus Analysis User’s Manual, 2012, Spatial
Modeling Execution&Output

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