nCode User Group Meeting 5 6,2016€¦ · • Automotive System Lab Testing • Uses data collected...

HBM Prenscia: Public

© 2016 HBM

nCode User Group Meeting | October 5‐6,2016

2016 nCode User Group Meeting

© 2016 HBM October 5-6, 2016 www.ncode.com


© 2016 HBM

Virtual Strain Gauge Correlation of Structural Components

Presented by: Marc BastaracheOctober 6th, 2016Tower International




© 2016 HBM

3Intro to Tower International ‐ Products

Body Structures Chassis Structures Energy & Other




© 2016 HBM

4Intro to Tower International ‐ Customers

North AmericaFord

ChryslerNissanToyota

BrazilVolkswagen

FiatHonda

EuropeVolkswagen

VolvoDiamlerFiatBMW

ChinaCherry




© 2016 HBM

5Intro to Tower International – CAE Capabilities

• Modal

• Frequency Response• Dynamic Stiffness

NVH

• Suspension Kinematics Kinematics

• Static Stiffness

• Static Stress Linear Structural

• Inertia Relief • Rear Impact

Crashworthiness• Front Impact

• Side Impact• Roof Impact• Front/Rear Post Impact

• Topology

Optimization• Design Sensitivity

• Extrusion

Process Simulation• Stamping

• Hydro‐Forming• Bushing Push In/Out• Welding• Bolt Clamping• Die Press Operation

• Non‐linear Static Stress Non‐linear Structural

• Quasi Static Fatigue Durability Analysis

• Vibration Fatigue




© 2016 HBM

6

• Automotive System Lab Testing• Uses data collected from a prototype vehicle that is

driven around the customer’s proving ground (PG)• Collected data

• Loads

• Strains

• Acceleration

• Displacement

• Calculated data

• Uses dynamics software to calculate loads atcertain points

• The proving ground data is edited to reduce test time• Time constraints

• Budget constraints

• Tests for large systems use lots of strain channels tohelp tune the large system for testing

Challenge Background

240 seconds 24 seconds




© 2016 HBM

7

• A component that is part of a short wheelbase (SWB) vehicle variant experienced issues using strain gauges to tune the frame for lab testing

• It was observed that the SWB component did not have a strain gauge in a location that was critical for correctly tuning the lab test

• A similar vehicle variant, the long wheelbase (LWB) was run on the same proving ground and contained a strain gauge in the SWB’s critical location

• The Challenge• Can nCode DesignLife’s virtual strain gauge (VSG) tool be used to create a

correlation between the SWB and LWB component’s strains?

• Can the virtual strain generated for the SWB component be used to create an accurate test?

Challenge/Scope




© 2016 HBM

8Glyph Setup




© 2016 HBM

9

• YES! With a strain ratio PG/VSG = 996.3/721.9 = 138%

Does the LWB component’s proving ground strain correlate well to the VSG strain?

LWBProving Ground

Range: 996.3 μe

LWBVirtual Strain Gauge

Range: 721.9 μe




© 2016 HBM

10

• And apply the strain ratio of 138% between LWB PG strain and VSG strain…

Calculating the SWB Component’s Equivalent Proving Ground Strain

SWBVirtual Strain Gauge

Range: 646.1 μe

SWBAdjusted

Virtual Strain Gauge

Range: 891.5 μe




© 2016 HBM

11

• Using nCode DesignLife’s virtual strain gauge tool, Tower was able to gain anunderstanding of the strain that SWB component should have seen on the provingground in the critical location

• Using the adjusted SWB strain we were able to tune the system test correctly andrun without the issues that were observed before strain could be correctly tuned

Conclusion




© 2016 HBM

www.hbmprenscia.com

Marc Bastarache

Tower InternationalCAE and Material Testing

1‐248‐675‐6039

[email protected]

Thank You!



Date post:	29-May-2020
Category:	Documents
Upload:	others
View:	1 times
Download:	0 times

nCode User Group Meeting 5 6,2016€¦ · • Automotive System Lab Testing • Uses data collected...

Documents