SIMULIA Ressourcen-Center

The present work will concentrate on the gear fatigue of automotive power transmission systems. Especially the strength of the bevel gears of the differential transmission has important influence on the durability of the whole transmission system. Therefore the bevel gears and pinions are made of hardened high strength steel. As an example the lecture shows a strength- and durability analysis of a differential gear. An accurate Finite Element Model is employed to provide a quantitative understanding of gear tooth contact behaviour under load. A rolling and sliding contact simulation between the bevel gears is performed to get the resulting stress distribution using the commercial Finite Element Analysis software Abaqus.

Customer Papers

The automotive and heavy-duty industries are heavy users of Computer Aided Engineering (CAE) for development, design and performance optimization of their products. As a technology driven company, the Sealing Products Group of Dana Holding Corporation utilizes this technology extensively, especially for metal cylinder head gaskets (CHG) and exhaust gaskets, so called Multi-Layer-Steel (MLS) gaskets. This paper provides an overview on accelerated simulation performance studies utilizing the latest SIMULIA technology for advanced sealing application from the Sealing Products Group of Dana Holding Corp. Furthermore it provides an outlook of steps to come.

Customer Papers

Brembo S.p.A produces mainly braking systems and components for automotive market. Actually, Brembo organization and business are quite complex due to the geographic dimension (Brembo is present in several countries worldwide both with manufacturing and engineering sites) , to the market dimension (Brembo produces for passengers cars, commercial vehicle, motorcycles, racing cars, OE, Aftermarket, etc...), and finally to the customers dimension; infact Brembo designs the braking system on specific customer and car.

Customer Papers

An Abaqus Extension, in the form of an Abaqus/CAE Plug-In, has been developed for modeling welding. The Plug-In enables an easy, efficient, model-tree based approach to setup all aspects of a welding model from within Abaqus/CAE by automating most of the repetitive, timeconsuming tasks associated with building a welding model in a traditional CAE environment. Examples of tasks supported by the Plug-In include weld-bead and pass definitions, automatic definition of steps and boundary conditions for each pass, automatic (but editable) creation of node sets for each pass to enable definition of temperature sensors, and set-up of both the thermal and mechanical analysis models.

Customer Papers

A methodology is presented for evaluating the safety of an accidental or intentionally applied accelerated cooling process. Accelerated cooling occurs due to increased heat transfer from the wetted surfaces. For steady state processes like pool boiling, the change across the various heat transfer regimes occurs at specific temperatures and due to extensive studies, the minimum and maximum limits of heat flux can be determined with reasonable accuracy. However, flood-cooling is not a steady state process and the boiling curve exhibits some transient distortion. A flood-cooling heat transfer model was developed based on a generalized correlation of single and two-phase forced flow combined with literature data for the modified heat transfer regimes during quenching of hot surfaces.

Customer Papers

Product development is becoming more complex. It involves not only system simulation requirements, but also the need to manage and share huge amounts of engineering information that is housed throughout the world. It quickly becomes complex when getting into detailed system simulation for powertrain applications such as sealing products.

Customer Papers

This paper introduces an alternative decohesion element that offers improved convergence characteristics over other formulations. The new element’s implementation as an Abaqus UEL is discussed, along with certain insights the authors have developed that illuminate at least some of the factors complicating convergence of cohesive-element models. Methods for improving convergence of delamination and disbond problems are presented and evaluated with respect to a canonical test case.

Customer Papers

Advanced hybrid laminates (AHL) are based on advanced metal alloys and involve the strategic placement of Fiber Metal Laminates (FML) and/or fiber prepreg only where necessary to enhance structural performance. Finite element analysis of these layered structures is quite complex involving simulation of interaction between metallic and composite layers, accurate prediction of in-plane and out-of-plane stresses, contact simulation and progressive failure analysis of metallic and composite layers. The finite element chosen should be able to accurately predict both in plane and out of plane stresses. This paper presents a study of isotropic, orthotropic, composite and hybrid structures under tension, bending, shear and combined loadings using various 2D and 3D finite elements and their accuracy in predicting stresses.

Customer Papers

In the modern design and manufacturing world, shorter development cycle times are being demanded. In addition, engineers are being asked to perform more analyses and studies to improve their products. To meet the challenge, engineers will seek more ways to increase robustness and productivity. With the continued integration of computational tools, such as the associative import between SolidWorks and Abaqus/CAE, it is possible to analyze and reiterate designs, materials, and structures in a more productive and efficient fashion.

Customer Papers

A finite element analysis methodology was developed to simulate brittle crack initiation, ductile or brittle crack propagation and ductile crack arrest in a single simulation using ABAQUS. Ductile fracture was modeled by employing element deletion when the equivalent plastic strain reached a critical value. Within the same FEM, brittle fracture was modeled by incorporating cohesive behavior between contact surfaces defined along the expected crack face. While this method was not as accurate as an FEM incorporating J integral calculations, its simplicity allowed simultaneous incorporation of brittle and ductile fracture.

Customer Papers

Modern sealing technology in powertrain and exhaust applications of the automotive and heavy-duty industries utilizes Multi-Layer-Steel (MLS) gaskets for cylinder head gaskets (CHG) and exhaust gaskets. In light of more stringent requirements towards emissions and fuel economy, the increased application of shear forces on those gaskets due to vibration and thermal expansion have a major influence on the durability and wear of the gasket layers.

Customer Papers