BON KOK WUI & TAN MING SHENG
Date – 27th August, 2013
A Total Solution for Automotive Helical Spring Design
APM Engineering & Research Sdn. Bhd.
Seating Systems
Complete Seating System from OEM RFQ.
New seating mechanisms (Track, Recliner, Height adjustment, Lumbar etc).
Suspension System
Range of coil, leaf and parabolic springs, air bellow.
Shock absorbers.
Corner Module.
Complete Leaf Spring Suspension Module.
Gas Spring
Climate Control
Radiator, Condenser cores and assembly.
Blower fan and shroud.
Complete A/C Cooling module.
Interiors and Plastics
Door Panel and Interior trims & head liners.
Instrument Panel, Bumper System
Company Background : APM Engineering & Research Sdn. Bhd.
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Current automotive design trend: Better Fuel Efficiency & Larger Cabin Space.
Consequences: Suspension design package reduced, complexity of design increased.
Design process become more complex due to the limitation of the design package. More and more consideration is required which is unable to capture by general design formulation.
CAE as a design tool to realize design blind spot and provide better understanding to the designer through virtual realization
Introduction
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Objectives
To simulate coil spring behavior along the working stroke during design stage in order to detect the potential risk prior to prototype making.
To evaluate Coil Spring design based on below criteria along the working stroke:
Load & Spring Constant
Principle Stresses & Shear Stresses
Interference with Surrounding Package
Rubber Force distribution
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Drawing and Design information for prototype
Generate FEA Report
Customer Input
Customer Approval
Preliminary Design Calculation
CAD Drawing
Computer Aided Engineering (CAE)
Load Analysis Stress Analysis
Rubber Force Analysis Interference Analysis
Feasibility Study
No No
No
Sample Development
Methodology
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Model & Load Case Description
In Vehicle Condition :
Upper seat is fixed in ALL degree of freedom . Displacement is imposed on the lower seat.
Imposed Displacement
Fixed
Coil Spring
[Steel] 3D Spring Seat
[Steel] 2D
Rubber Seat
[Rubber] 3D
Surrounding Packages
[Steel] 2D
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Principle Stress Shear Stress
Detailed Analysis Result : Principle & Shear Stress
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Bottom View
Cross-section View
Iso View
Detailed Analysis Result : Interference with Surrounding Packages
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Mating Parts Dust Cover
Rubber Seat Spring Seat
Detailed Analysis Result : Interference with Surrounding Packages
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Mating Parts Dust Cover
Rubber Seat Spring Seat
Detailed Analysis Result : Interference with Surrounding Packages
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Conclusions
From the simulation, the potential risk is identified. Therefore design changes can be made during the initial design stage.
A full picture of helical spring behavior along the working stroke is illustrated through simulation to enable design engineer for a better judgement ensuring fulfillment of customer’s requirement.
CAE provides a total solution for automotive helical spring. Not only a higher efficient and comprehensive tool, it is also an enhancement for the helical spring design process.
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