www.ifbautomotive.com

IFB Automotive Private Limited : CAE Division

CAE Safety and Comfort is Our Concern

1974 ▶ IFB INDUSTRIES, KOLKATA Main Products: Fine blanking Components & Sub-assemblies

1984 ▶ IFB INDUSTRIES, BANGALORE Main Products: Fine blanking & Automotive Sub-assemblies

1989 ▶ IFB AUTOMOTIVE PRIVATE LIMITED, BANGALORE Main Products: Seat, Door , Latch Mechanisms & Automotive Motors

1990 ▶ IFB HOME APPLIANCES , GOA Main Products: Washing m/c, Dish washer, Micro wave Oven, A/C, Refrigerator

2003

▶ IFB AUTOMOTIVE R&D

CENTER.- BANGALORE

2005 ▶ IFB AUTOMOTIVE, CHENNAI 2007 ▶ IFB AUTOMOTIVE, PUNE ▶ IFB AUTOMOTIVE, UTTARAKAND

2007

▶ IFB AUTOMOTIVE, BINOLA Satellite plant of IFB APL Bangalore

2012

▶ IFB APL : CAE Division Analysis/Simulations: NVH, MBD, CFD, FE-Structure, Manufacturing & Optimization

CAE Safety and Comfort is Our Concern

IFB’s Domain Expertise

Country spirit Packed Sea Food

IFB AGRO

Fine Blanking

Tools Fine Blanking

Components

IFB INDUSTRIES

IFB HOME APPLIANCES

Washing machine Refrigerator Dryer

Air conditions Micro-wave Dish washer

IFB AUTOMOTIVE

Seating Systems Door Systems

Latches Motors

CAE

Automotive Door

Systems

Automotive Seating

Systems Motors

Home Appliance

Products

1. Sliders - Power &

Manual

2. Recliners - Power

& Manual

3. Height Adjusters -

Drum & Pump

4. Floor & RSB

Latches

5. FSB Frames

6. Adjustable Armrest

7. Two Position

Adjusters

1. Manual Window

Regulators

2. Power Window

Regulators

3. Double Guide Rail

Window

Regulators

4. Door Modules

Automotive Motors:

1. Radiator Motors

2. Condenser Motors

3. Blower Motors

4. Window Regulator

Motors

Appliance Motors:

1. Universal Motors

2. Single Phase

Induction Motors

3. BLDC Motors

1. Door Latches

2. Hood Latches

3. Trunk Lid Latches

4. Door Strikers

5. Hinges

Automotive Latch

Mechanism

FL Washing

Machine

FL Washing

Machine

Microwave Ovens

Dishwasher

Air Conditioner

Refrigerator

Clothes Dryer

Chimneys

Modular Kitchen

Product Range of IFB Automotive & Home Appliance

CAE

IFB’s Automotive Products in Cars

Rear Seat Back

Latch

Seat Slider cum Recliner with

Height Adjuster

Compact High

Strength Seat Recliner

Seat Floor Latch

Rear Seat TPA

Manual and

Powered Window

Regulator

Door Latch

Hood Latch

Trunk lid latch

Door Strikers

Hinges

FSB Frames Adjustable Arm Rest

Automotive

Motor

CAE

Home Appliance Products

Home Appliance

Products

Front & Top Loader Washing Machine

Refrigerator Microwave Ovens Dishwasher

Clothes Dryer

CAE

Fine Blanking vs Conventional Blanking

CAE

IFB Industries, Bangalore

Test Lab Facilities : IFB Automotive, Bangalore

Impact Load Testing

Vibration cum Environmental Chamber

Slider Endurance Testing

Seat Belt Anchorage Testing

Dynamic Crash Test

Recliner Operational Durability Testing

Recliner Twisted Hinge Arm Testing

Rising Load Test Machine

Recliner Moment Durability Test

Recliner Static Strength Testing

CAE

Test Lab Facilities : IFB Automotive, Bangalore

Window Regulator Endurance Testing

Door Slam Testing

Dust Spray Testing

Thermal Shock Testing

Endurance Test Machine – Door Latch

CAE

Test Lab Facilities : IFB Home Appliance, Goa

Mechanical Testing Lab

Environmental Test Rooms Safety Test Lab EMI/EMC testing Lab

CAE

Test Lab Facilities : IFB Home Appliance, Goa

Vibration Shaker Test Bevel Hitting

Side Clamping test Drop test Compressive Resist test

Semi Anechoic Chamber

CAE

IFB CAE - Predictive Engineering

Computer Aided Engineering (CAE)

CAE

Why CAE? & Benefits of CAE

Why CAE?

1. Staying competitive in today’s market.

2. Product performance can be ensured along with reduction in cost & weight of

the product.

3. Plays a fundamental role for developing the Products and Processes from

“Concept → Mass Production”.

CAE

Benefit of CAE

Product Design &

Development

Design Inputs &

Planning Process Design &

Development SOP Support

Specification /

SOR / SOW

Benchmark Data

TGR & TGW

Product Reliability

Study

Physical Sample

Design Goals

Reliability and

Quality Goals

Preliminary BOM,

PFC, SCs & CCs

Layout Study

Design of Parts

and Assembly

DFMEA, DFM &

DFA

Design Reviews &

Verification

Prototype Making

Design Validation

Engg. Drawings

with GD & T

RE & RE. Engg.

Design Alternates

Styling – Class A

& B Surfaces

Concept Production

PFC

PFMEA

Jig, Fixture, Gauge

& Test Rig

CNC Tool path

Prototype Build

Floor Plan Layout

Production Control

Plan

SOP, MSA, SPC,

etc.

Packaging

specifications

Struct.: Linear,

Non-linear, etc.

Crashworthiness &

Safety

NVH Simulation

MBD Simulation

CFD Simulation

Manuf. Simulation

Durability /

Fatigue

Tolerance Analysis

Design

Optimization

Analysis and

Optimization

VA / VE

Design Updates

based on DV & PV

results

Updates in BOM,

PFC, SCs & CCs

ECR / ECN

Design of

Experiment (DOE)

Failure Analysis

Customer

Satisfaction

CAD Tools: CATIA V5, CATIA V4, NX Design, I-DEAS, Pro-E, MDT & Inventor, AutoCAD, IronCAD & PTC's Windchill

CAE Tools: LS-DYNA, ADAMS, HyperWorks (Radioss, AcuSolve, OptiStruct, HyperForm, etc.), FormingSuite & NX Nastran

IFB – Engineering Solution Offerings

CAE

FE Simulation

Quasi-Static, Linear & Non-linear Static

Crashworthiness & Safety

Sequential Drop Analysis

Fatigue & Fracture Analysis

Manufacturing Simulation

Mold Flow Analysis

Sheet Metal Stamping & Forging

Fine Blanking Tool Simulation

CFD Simulation

Fluid Flow Simulation

Multiphase Flow Simulation

Thermal Analysis

Rotating (Domain) Simulation

Optimization Topology (Space & Size)

Topography (Geometry)

Combination of T& T

MBD Simulation

Kinematic Simulation

Dynamic Simulation

Design Optimization

NVH Simulation

Vibration Analysis (All Types)

Noise Analysis (All Types)

Harshness Analysis

Vibro-fatigue Analysis

Concept Design Final Design

Expertise in different types of product & analysis /simulation

Well defined CAE Methodology / Procedures with experienced CAE Analysts

Compliance to regulation requirements

Experience in using wide range of simulation tools

Focuses on CAE driven Design Phases : Concept design, Detailed Engg and Refinement Engg.

IFB’s CAE Capabilities

CAE

IFB CAE - Predictive Engineering

CAE Case Studies

Automotive & Home Appliance Products

CAE

CAE

Case Studies : CAE – Analysis & Simulations

1. Finite Element (FE) Simulation – Structures

2. Noise & Vibration Simulation

3. Multi-Body Dynamic (MBD) Simulation – Rigid and Flexible

4. Computational Fluid Dynamic (CFD) Simulation

5. Manufacturing Simulation

6. Design Optimization

Objective:

To predict the safety, strength & stiffness of Seat

System using the global regulations.

Challenge:

No change is allowed in Topology and

Topography.

Increase in safety and reduction in weight & cost.

The correlation level must be closer and

acceptable.

Observation:

Lower & Upper Rails are deformed and

peeled-off.

The stress and effective plastic strain crossed

the design limit.

Solution:

Local reinforcement bracket is introduced to

increase strength & stiffness of Lower & Upper

Rails.

Design - Major parts are modified.

Conclusion:

No peel-off found in the modified design

Case Study - 1: Crashworthiness Analysis

95 %le Dummy Input Crash Pulse

Rails Peeled-off Reinforcement Bracket is introduced

Animation : Frontal Crash

Existing Design Modified Design

Acc

eler

ati

on

(g

)

Time (Sec)

CAE

Objective:

To predict the safety, strength & stiffness of Seat

System using the global regulations.

Challenge:

No change is allowed in Topology and Topography.

Increase in safety and reduction in weight & cost.

The correlation level must be closer and acceptable.

Observation:

Observed the deformation in Upper adaptor mounting

area with back frame.

Solution:

Local reinforcement bracket is introduced to increase

the strength & stiffness of Lower & Upper Rails.

Design - Major parts are modified.

Conclusion:

No peel-off found in the modified design

Case Study - 2: Luggage Retention Analysis

Luggage retention test with 18Kg Load Input Pulse

vonMises Stress Effective Plastic Strain

Animation : Frontal Crash

Acc

eler

ati

on

(g

)

Time (Sec)

CAE

18Kg mass

Objective:

To predict the strength and stiffness of “Seat

System” by referring the global regulations.

Challenge:

No change in geometry is allowed due to space

constraints.

Increase in strength, stiffness and reduction in

weight & cost.

The correlation level must be closer and acceptable.

Observation:

Upper Rail of Track mechanism is deformed and

peeled-off.

The stress and strain crossed the design limit in

Upper Rail.

Solution:

Flange is introduced in the Upper Rail at weak zone

to increase the strength & stiffness.

Conclusion:

No peel-off found in the improved design.

Case Study - 3: Seat Belt Anchorage Analysis

Load & Boundary Condition Input Graph

Upper Rails – Deformed Flange is introduced

Animation - Seat Belt Anchorage

Existing Design Modified Design

Existing Design Modified Design

CAE

Objective:

To predict the strength & stiffness of Seat

System.

Challenge:

No change is allowed in Topology and

Topography.

Increase in strength & stiffness along with

reduction in weight & cost.

The correlation level must be closer and

acceptable.

Observation:

The maximum displacement of the head rest

is 46.98 mm which is well below 102 mm.

Solution:

The strength & stiffness of the seat system is

meeting the design intent. Hence, there is no

design improvement solutions.

Conclusion:

Since the design intent is met, there is no

design change in the seat system.

Case Study - 4: Head Rest Performance Analysis

CAE

Max ‘Y’ Displacement : 46.98 mm Max ‘X’ Displacement : 0.172 mm

Initial

position

Displaced

position

Displacement in the Frame

X

Z

Y

Load & Boundary Condition Input Graph

Case Study - 6: Insertion force Analysis

Objective:

To predict the force required to assemble the Bearing

with the Shaft of Radiator Motor by considering the

below cases

Case 1: 8 microns interference.

Case 2: 26 microns interference.

Challenge:

Predict the force required to assemble the Bearing

with the Shaft of Radiator Motor without changing

the Geometry, Material and Tolerance (8 & 26

microns interference).

Observation:

With 8 microns interference, the assembly force is

192.8 Kgf.

With 26 microns interference, the assembly force is

711.5 Kgf.

Solution:

Since the predicted insertion force is closer to the

experimental force, the design of the parts need not

be modified.

Conclusion:

Correlation between analysis result and experimental

results found closer.

Constrained all degrees of

freedom on face of flange

Enforced

displacement

Maximum contact pressure= 6.40E+4 MPa

Case 1: 8 microns

Maximum contact pressure= 7.27E+4 MPa

Case 2: 26 microns

CAE

Case Study - 7: Sequential Drop Analysis

Front Load Washing Machine Input Parameters

Drop Animation

Objective:

To predict the strength & stiffness of the major parts

of the Washing Machine.

Challenge:

No change is allowed in Topology and Topography.

Malfunction of WM is not allowed.

Correlation level must be closer and acceptable.

Observation:

Cabinet: Deformation found more in Corner Drops

compared with Edge Drops.

The stress and strain level is beyond the design limit

at Transportation Bolt.

Solution:

The emboss in Cabinet is modified to increase the

strength and stiffness.

Design and properties of thermocol is optimized.

Conclusion:

The damage level is within the design intent.

Correlation Level : Virtual Result found closer to the Physical test

Transportation Bolt Area Thermocol (EPS Foam)

Vertical Drops

Edge Drops

Corner Drops

CAE

1. Velocity

2. Acceleration

3. Drop Height

Case Study - 8: Modal Analysis of Cabinet

Objective:

To predict the natural frequencies and Mode Shapes

of the Cabinet Assembly.

Challenge:

No resonance condition is acceptable.

Malfunction of Washing Machine is not permitted.

Observation:

The natural frequencies are in the critical range in

Door Assembly & Rear Cover.

Solution:

Snap joint or gasket to be provided b/w Panel Housing

and Door Assembly.

No. of joints to be increased b/w Cabinet and Rear

Cover.

Provide constraint or reduce clearance b/w Rear

Cover and Rear Plate (e.g. by providing rubber

sleeve).

Conclusion:

The fundamental frequencies of suggested design

improvements does not falls in the resonance zone.

CAE

Design improvement Suggestion

Constraint all DOF

1. Geometry

2. Material

3. Mass

Animation

Input Parameters

Case Study - 10: Random Vibration Analysis

Objective:

To study the strength and stiffness of “Door Latch” under

Random Vibration condition. Input Source: Road

Roughness or Engine Vibration.

Challenge:

Damage of parts are not acceptable.

Malfunction of Door Latch is not permitted.

Increase in strength, stiffness & reduction in weight & cost.

Observation:

The maximum RMS Von-Misses stress found to be 8.4 MPa

and the 3σ value is 25.2 MPa. This is within the endurance

limit of the material.

Negligible 3σ disp. is observed in the Door Latch Assembly.

Solution:

The strength & stiffness of the Door Latch assembly is

meeting the design intent. Hence, there is no design

improvement solutions.

Conclusion:

Since the design intent is met, there is no design change in the

Door Latch Assembly.

CAE

Animation

Base

acceleration

Mounting locations

Input spectrum Boundary Condition

Node with Maximum

Modal Participation

RMS Stress : 8.4 MPa RMS Relative Displacement : Negligible

Case Study - 11: Noise Analysis – WM Motor

Load & Boundary Condition Input Graph

Animation

Objective:

To predict the acoustic power of WM Motor and modify

the design to reduce the noise and improve the

performance.

Challenge:

Motor must meet global regulations and standards.

No change in Cost, Manuf. & Assembly processes.

Reduce / eliminate the noise without the loss of

performance and safety.

Observation:

1st Fundamental Frequency of 865Hz was observed on

the shaft with up-down motion - Y direction.

2nd Frequency of 868Hz was observed on the shaft with

side-side motion - X direction.

Vibro-acoustic – ATV method was used to predict the

noise level. Panel contribution was adopted to estimate

the probable source of noise.

Solution:

The design of Stack & Housing are to be modified to

reduce the noise.

Conclusion:

Noise level is reduced

Acoustic Response analysis Panel Contribution Analysis

ATV : Acoustic Transfer Vector)

CAE

Case Study – 12: Dynamic Balancing Simulation (Optimization)

Input Graph – Drum Rotation : CCW

Objective:

To study the displacement of Oscillation Group under

extreme Dynamic conditions. Bearing Housing material is

changed from Cast Iron to Plastic

Challenge:

Oscillation Group should not knockout Cabinet at extreme

Dynamic conditions.

Malfunction of WM is not allowed during Spin.

Mass of 1.5Kg to be kept at Front & Rear position of the

Drum.

Observation:

The clearance b/w Oscillation Group & Cabinet is within

the design intent.

Change in CG with the Plastic Bearing Housing

Weight distribution is changed.

Solution:

Weight distribution to be optimized to avoid walking

phenomenon.

The displacement of Oscillation Group is to be reduced to

increase the life.

Conclusion:

The displacement is within the limit in the modified

design

CAE

Animation: Dynamic Balancing Simulation

1.5 Kg imbalance mass

Front Rear Front Rear

Displacement at Origin Front & Side View

MaterialX - Direction

(mm)

Y - Direction

(mm)

Z - Direction

(mm)

Plastic 13.49 8.77 19.90

Cast Iron 13.28 8.95 19.41

MaterialX - Direction

(mm)

Y - Direction

(mm)

Z - Direction

(mm)

Plastic 13.20 15.45 28.36

Cast Iron 12.99 17.43 27.64

Displacement at Origin - Mass at Front

Displacement at Origin - Mass at Rear

Objective:

To predict and improve the “Air Flow Rate

(m3/hr.)” of Radiator Axial Fan.

Challenge:

Reduction in Natural Frequency of Shroud is not

acceptable.

Increase in cooling performance, reduction in

weight & cost.

The correlation level must be greater than 90%.

Observation:

The Air Flow Rate (m3/hr.) is found to be less

than the specification.

Solution:

4 small ribs are removed in the Shroud.

No. of Shroud mounting points are increased

from 4 to 6.

Conclusion:

Air-Flow-Rate is achieved in the improved

design.

Case Study - 13: CFD : Air Flow Rate

Load & Boundary Condition

Correlation Level : 0.2% - 13.9%

Animation: Velocity Vector Flow

CAE

3D Model – Shroud & Fan

Case Study - 16: SMS - Formability Simulation

Forming Limit Diagram (Ref.)

Objective:

To predict the formability through FLD, material

utilization, variation in thickness, Safe & Critical

Zones, etc.

Challenge:

Major change in geometry is not allowed.

Optimize the material utilization.

Material thinning’ thickening, etc. must be within the

acceptable limit.

Observation:

Thinning and Thickening were seen near forming

zones.

Solution:

Sudden change in geometry are to be modified at the

fail zones.

Forming radii has to be increased by considering

DFM.

Conclusion:

Thinning and Thickening were not seen in simplified

design.

Car Seat Frame – Side Bracket

CAE

Forming Zone

Safety Zone

Thickening (Wrinkle): Stretch &

Compression with material thickening.

Thinning (Tight Panel ): Stretch in two

directions with highest material thinning.

Thickening: Wrinkles will occur.

Safe: Area below Forming Limit Curve.

Fail: Area above Forming Limit Curve.

Case Study - 17: Rear Tub - Moldflow Simulation

Feed System Details CAD Model

CAE

Cooling Circuit Details

Cavity Side Core Side

Objective:

To study the parameters like Fill, Flow, Cool, warp, etc.

to achieve the uniform and balanced fill pattern and

optimize the processing parameter.

Challenge:

Selecting the gate location and type of gating system

Runner design and cooling system design

Material selection

Optimize the process parameter to achieve quality

criteria

Observation:

Fill pattern is balanced and uniform

Weld lines fusing at higher temperature

Higher volumetric shrinkage is observed at thicker cross

section region but are within acceptable limits

Warpage observed is within the limits along the Z

direction (assembly area)

Solution:

The optimized design and process parameter is arrived

by performing various iterations

Conclusion:

Design and process parameters are optimized and met the

quality criteria.

Case Study - 18: Door Outer - Moldflow Simulation

Feed System Details

Objective:

To study the parameters like Fill, Flow, Cool, warp, etc. to

achieve the uniform and balanced fill pattern using

sequential valve gating system.

Challenge:

Selecting the gate location and setting the sequential gates

timings.

Material selection

Optimize the process parameter to achieve quality criteria

Observation:

Fill pattern is balanced and uniform

Weld lines fusing at higher temperature and are placed at

the rear end of the part

Volumetric shrinkage is uniform. Higher volumetric

shrinkage is observed near the boss region.

Warpage observed within the limits in Z direction.

Solution:

The optimized design and process parameters are arrived

by performing various iterations

Conclusion:

Design and process parameters are optimized to obtain

quality part

CAD Model

CAE

Sequential Gating Timing Details

Optimization of Design

CAE

IFB's Optimization Capabilities

Option - 1: Topology Optimization: Generates an optimized material distribution for

a set of loads and constraints within a given design space / size.

Option - 2: Topography Optimization: Generates an optimized distribution of shape

based reinforcements.

Option - 3: Shape & Size Optimization: General size and shape optimization problems

can be solved. Variables can be assigned to properties, which control the thickness,

area, moments of inertia, stiffness, and non-structural mass of elements in the model.

1. Benchmarking

2. Yield Improvement

3. Weight Reduction

4. Alternative Material

5. Alternative Manufacturing Process

6. Reduction in thickness

7. Part Commonization

8. Part Count Reduction

Case Study - 19: Optimization – Alternate Manufacturing Process

Sintering Process Fine Blanking Process

Shear Strength: 8.7 KN

Existing Design – 2 Parts New Design – Single Part Objective:

To predict the Shear & Holding Strengths of Pin/Lug

(change in manufacturing process).

Challenge:

Since the part is in mass production, change in

geometry is not acceptable.

Strength of the Pin / Lug must be better than the

existing part.

Cost of the part to be reduced.

Observation:

Pin is shearing at 8.7 KN in production part.

The plastic strain is > at design limit at 8.7 KN

Solution:

Gear & Pin can be integrated in the proposed

manufacturing process.

The root radius of Lug can be changed by considering

DFM.

Conclusion:

The Lug is not even failing at 10 KN load & plastic

strain is less by 15%

Part Name: Plate Shift Drum Stopper

Lug

Pin

Shear Strength: >10.0 KN

Load

Holding Strength: >10.0 KN

Load

Holding Strength: 4.0 KN

CAE

Automotive Seating Mechanism : Product Validation Flow

Lock Breakdown

Strength

Track Retraction

Strength

Seat Belt

Anchorage

Crash with Rigid

Dummy

Ensures Lock Strength

Ensures Lock &

Rail Peel-Off

Strength

Ensures Lock, Rail

Peel-Off & Seat

Belt Anchorage

Strength

Ensures Total

Seat Strength

Design

Finalization

Design Modification

Fail

Fail

Fa

il

Fail

Note: Sub-system

& System

CAE

Side Clamping Test

Vertical Bounce Test

Horizontal

Bounce Test

Bevel Hitting Test

No damage, part separation,

breakage, etc. are acceptable

No malfunction of

WM is acceptable

after completing

the test

Design Modification

Fa

il

Fail

Fail

Fail

Sequential Drop Test (9)

Fail

Note: Washing Machine must be in

fully packed condition No damage

is acceptable

No damage, part separation,

breakage, etc. are acceptable

No damage, part separation,

breakage, etc. are acceptable

Implicit

Explicit

Final

Design

CAE

Home Appliance : Transportation Test : Product Validation Flow

Why to choose IFB for CAE Simulations / Analyses

IFB – Engineering Solution Offerings

CAE

1. Increasing Efficiency: State-Of-The-Art computer simulations save time and cost

2. Best Solutions: With our innovate solutions, IFB will help you to get ahead of the competition

3. Reliability: High planning & cost reliability, Error-Free order fulfillment and on-time delivery

4. Flexibility: IFB respond quickly & flexibly while providing optimum quality

5. Customer Proximity: Our employees work either on your premises or in one of our branches in your area

6. Quality Credentials:

DSIR Certificate (R&D Center)

ISO 9000 & QS 9000

ISO TS-16949

ISO 14001

HMIL 100 PPM & Ford Q1

BM: TECOSIM

IFB Automotive Private Limited #16, Visveswariah Industrial Estate,

1st Main Road, Off Whitefield Road, Mahadevapura,

Bangalore, Karnataka, India - 560 048

Tel (Board) : 91 80 39884450

Fax : 91 80 39842778

Contact : Mr. M.RAMALINGAM

Head – CAE Division

Phone (Dir) : 91 80 39842376

Mobile : 91 80 9343769920

E-mail : rams@ifbautomotive.com

CAE