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Minimising Mass and Increasing Durability of a Vehicle Suspension System Using HyperStudy & OptiStruct
Technology Category
- Robots - Autonomous Guided Vehicles (AGV)
- Sensors - Torque Sensors
Applicable Industries
- Automotive
- Equipment & Machinery
Applicable Functions
- Procurement
- Product Research & Development
Use Cases
- Root Cause Analysis & Diagnosis
- Vehicle Performance Monitoring
Services
- System Integration
The Challenge
Gestamp, a global chassis component supplier, was faced with the challenge of reducing the mass and increasing the durability of a rear twist beam (RTB) suspension system. The RTB design is a complex task that requires careful consideration of elastokinematic performance in addition to meeting stiffness and durability targets. The design of experiments (DOE) and optimisation methods were being used to explore the available design space and minimise the mass of a low cost RTB design. The durability requirement was identified as one of the main mass drivers for this type of RTB design. The design of a “U Section” RTB typically requires consideration of several interlinked targets, including Roll Stiffness and Roll Steer, which are strongly influenced by the shape, position and gauge of the torsion element.
About The Customer
Gestamp is a global chassis component supplier for customers such as Ford, VW, BMW and Honda. Its technical centres which are based in the UK, Spain and Germany support an expanding global business with manufacturing sites throughout the world in developing low cost, high volume chassis products. Component mass and cost (strongly linked to mass) are drivers for every customer and Gestamp have been using an optimisation driven design process, based on Altair products, since 2005. Gestamp has recognised the potential for mass reduction through optimisation of a “U” section design.
The Solution
To address the challenge, Gestamp selected Altair to develop a set of custom tools, referred to as “The RTB Toolbox,” which can be used to generate an initial RTB concept that meets Kinematics and Compliance (K&C) requirements such as Roll Stiffness/Steer, thereby eliminating an initial “trial and error” design loop. The software used the functionality available within high-performance preprocessor HyperMesh to set up shape design variables for each component in the RTB assembly. HyperStudy was used to control DOE studies, which provided a detailed understanding of the sensitivity of each target to input parameters. This was followed by a final optimisation step from which the concept surfaces were generated. The next stage of the design process was to create a CAD model from the optimised Toolbox output. This model served as a baseline for work to meet durability and strength criteria.
Operational Impact
Quantitative Benefit
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