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Robust Race Car Design - ansys.com · PrepPost to simulate the stiffness of ... ANSYS solvers...

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ANSYS ADVANTAGE Volume VIII | Issue 1 | 2014 © 2014 ANSYS, INC. ACADEMIC STUDENT TEAM T he Harbin Institute of Technology (HIT) racing team is very familiar with the use of simulation for automotive design. The team has participated in Formula Student Germany and Formula Student Japan; it received second prize for Formula Student China in 2013. ANSYS software has been instrumental in designing many aspects of the team's lightweight vehicle, including the unique carbon-fiber monocoque, aerodynamics and the intake system. Of the 58 mem- bers on the team, 30 use ANSYS tools to achieve their individual design goals by employing ANSYS Mechanical, ANSYS Fluent, ANSYS Composite PrepPost, ANSYS DesignXplorer and ANSYS LS-DYNA. The team overcame design challenges using parametric simulation and opti- mization. The students perform parame- terization using ANSYS DesignXplorer to create a faster car that is also powerful, lightweight and reliable. Multiphysics capabilities accessed through ANSYS Workbench allow HIT team members to develop models that closely match real- world conditions. The HIT team used ANSYS Composite PrepPost to simulate the stiffness of the vehicle’s monocoque to reduce the weight of the layered composite body. Team members combined experiments with ANSYS simulation to develop the composites material. The intuitive inter- face of Composite PrepPost efficiently defined the materials, plies and stack- ing sequences; it also offered a wide choice of state-of-the-art failure criteria. ANSYS solvers provided the foundation for By Hao Yuzhou, Chassis Design and Finite Element Analysis, HIT Racing Team, Harbin Institute of Technology, Weihai, China accurate results, and data from physical testing was consistent with the analyses. The software helped the team to improve the stiffness of the chassis and reduce local stress concentrations. The final monocoque weighed 18.4 kg, which is 2.6 kg lighter than the previous version. The team also achieved a 14 percent improve- ment in the stiffness-to-weight ratio. The air intake for the vehicle was designed with the help of fluid–structure interaction (FSI) that combined Fluent with ANSYS Mechanical software. The intake system for the engine experiences negative pressure during operation. By collecting manifold pressure sensor data, the HIT team found that the peak negative pressure is 0.7 bar in the intake manifold. This level of negative pressure can change the shape of the air intake sys- tem, which, in turn, influences the flow field inside the manifold and can even destroy the structure of the air intake. ROBUST RACE CAR DESIGN ANSYS software is instrumental in designing the HIT racing team's lightweight vehicle. The team achieved a 14 percent improvement in the stiffness-to-weight ratio of the carbon- fiber monocoque. Harbin Institute of Technology racing team and car
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ANSYS ADVANTAGE Volume VIII | Issue 1 | 2014 © 2014 ANSYS, INC.

ACADEMIC STUDENT TEAM

The Harbin Institute of Technology (HIT) racing team is very familiar with the use of simulation for automotive design. The team has participated in

Formula Student Germany and Formula Student Japan; it received second prize for Formula Student China in 2013. ANSYS software has been instrumental in designing many aspects of the team's lightweight vehicle, including the unique carbon-fiber monocoque, aerodynamics and the intake system. Of the 58 mem-bers on the team, 30 use ANSYS tools to achieve their individual design goals by employing ANSYS Mechanical, ANSYS Fluent, ANSYS Composite PrepPost, ANSYS DesignXplorer and ANSYS LS-DYNA. The team overcame design challenges using parametric simulation and opti-mization. The students perform parame-terization using ANSYS DesignXplorer to create a faster car that is also powerful, lightweight and reliable. Multiphysics capabilities accessed through ANSYS Workbench allow HIT team members to develop models that closely match real-world conditions. The HIT team used ANSYS Composite PrepPost to simulate the stiffness of the vehicle’s monocoque to reduce the weight of the layered composite body. Team members combined experiments with ANSYS simulation to develop the composites material. The intuitive inter-face of Composite PrepPost efficiently defined the materials, plies and stack-ing sequences; it also offered a wide choice of state-of-the-art failure criteria. ANSYS solvers provided the foundation for

By Hao Yuzhou, Chassis Design and Finite Element Analysis, HIT Racing Team, Harbin Institute of Technology, Weihai, China

accurate results, and data from physical testing was consistent with the analyses. The software helped the team to improve the stiffness of the chassis and reduce

local stress concentrations. The final monocoque weighed 18.4 kg, which is 2.6 kg lighter than the previous version. The team also achieved a 14 percent improve-ment in the stiffness-to-weight ratio. The air intake for the vehicle was designed with the help of fluid–structure interaction (FSI) that combined Fluent with ANSYS Mechanical software. The intake system for the engine experiences negative pressure during operation. By collecting manifold pressure sensor data, the HIT team found that the peak negative pressure is 0.7 bar in the intake manifold. This level of negative pressure can change the shape of the air intake sys-tem, which, in turn, influences the flow field inside the manifold and can even destroy the structure of the air intake.

Robust Race caR DesignANSYS software is instrumental in designing the HIT racing team's lightweight vehicle.

The team achieved a 14 percent improvement in the stiffness-to-weight ratio of the carbon-fiber monocoque.

Harbin Institute of Technology racing team and car

ANSYS ADVANTAGE Volume VIII | Issue 1 | 2014 © 2014 ANSYS, INC.

ACADEMIC STUDENT TEAM

Fluid–structure interaction simulation of air intake. The team needed to fi nd a design that would deform less than 0.5 mm under negative pressure so that the air fl ow would not be infl uenced.

Since the team uses carbon-fi ber compos-ites material for the air intake system, FSI system analysis was used to ensure over-all stiff ness, weight reduction and opti-mization of the layer design. This pervasive use of simulation was enabled through formal training by ANSYS that allowed the team to begin simulation early in the design process. In addition, team members who were expe-rienced with simulation worked with an expert ANSYS engineer to develop best practices. The team found that ANSYS Workbench was easy to learn for new users, the mesh control is good, and sim-ulation results are accurate. Using engineering simulation gave the team the ability to explore many designs and manufacture only the best one. For future competition vehicles, the HIT racing team will conduct further simu-lations, so they plan to train even more team members in the use of ANSYS soft-ware and employ additional modules to conduct coupled simulations.

Vehicle aerodynamics analysis

Learning and Making Engineering FunEvery year, students around the world use simulation in engineering competitions that are not only fun but prepare them for future careers.

Maximum total deformation simulation was used to obtain torsional stiff ness for the monocoque vehicle body, an important factor in its performance.

The team air intake for the vehicle was designed with the help of fl uid–structure interaction analysis.


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