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Development of a multifunctional truck cross member made of continuous fiber reinforced plastics

Lightweight design of trucks enables to increase the payload and represents a way to reduce the fuel consumption per transported weight. Many engineers around the world are focusing on this topic. One idea to handle this issue is to combine several vehicle parts or functions in an integrated module. This contribution shows the development of a cross member made of a combination of continuous fiber reinforced plastic and steel. Beside the function as an important structure of the truck main frame, the part represents a liquid/CNG reservoir at the same time. The management of design issues, the assessment regarding stiffness and strength was the major focus of the project.

Customer Papers

Development of a multifunctional truck cross member made of continuous fiber reinforced plastics
XFEM Simulation of Radial-Median Crack Evolution in Knoop Indentation of Brittle Materials

In sharp indentation of brittle materials, a complex three-dimensional stress field evolves in the material beneath the indenter and may cause cracking. During unloading, a tensile residual stress field drives the crack to its final semi-elliptical shape. The so-induced crack can be used for e.g. crack growth experiments, but for which the initial crack size and shape have to be known. For the analysis of the crack evolution in a material subject to a complex stress field, which changes with position, time and crack advancement, the extended finite element method (XFEM) represents a useful tool.

Customer Papers

XFEM Simulation of Radial-Median Crack Evolution in Knoop Indentation of Brittle Materials
Robust and optimal strain gauge positions for blade vibration testing

The maximal dynamic stresses on turbo machinery blades used for predicting end of life due to high cycle fatigue (HCF) are obtained from the correlation between an FE modal analysis and dynamic strain measurements. Still today it is rather common to use sets of strain gauges to measure the dynamic strains. A particular challenge in preparation of blade vibration measurement is the selection of locations and directions for strain gauges to be mounted, for capturing dynamic blade behavior of various mode-families.

Customer Papers

Robust and optimal strain gauge positions for blade vibration testing
The Effect of Rubber in Strength Analysis for Strut Insulator Assembly

The strut insulator assembly in the suspension system which supports shock absorber, spring and bump stopper takes large upward load when vehicle crosses pot hole or speed bump with high speed. As the permanent deformation of insulator bracket could cause noise problem, the development of insulator bracket strength is required. Though the main bumper stopper load applied to steel bracket directly in the inner core type insulator, there is rubber between steel bracket and bumper stopper in the cup molded type insulator. Because there could be some convergence problem caused by large deformation of rubber, the modeling and strength analysis procedure for the cup molded type insulator is set up in this study. A series of step-by-step trials would give an insight in setting up an analysis procedure of similar problem.

Customer Papers

The Effect of Rubber in Strength Analysis for Strut Insulator Assembly
Simulation Driven Design for Manufacture of a Pressed Composite Automotive Tailgate

A current key automotive industry initiative is delivery of mass savings through the use of lightweight materials, to reduce vehicle C02 emissions. Penso were commissioned by a European automotive OEM to design and manufacture a continuous fibre reinforced composite tailgate prototype. The new carbon fibre design had to meet all existing strength and stiffness targets, whilst maintaining existing A-surface geometry and all hardware. The three main parts of the tailgate considered for light weighting were the tailgate inner panel, tailgate outer panel and spoiler mechanism carrier. An optimised laminate design was developed by the engineering team using a non-linear static FE analysis performed with Abaqus/Standard.

Customer Papers

Simulation Driven Design for Manufacture of a Pressed Composite Automotive Tailgate

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New Release – R2019X

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