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Tommy Tran

Tommy Tran

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Section Reviewed

Notes

ACP (Pre)

Engineering Data

  • Material data seems ordinary

  • 4130 Chromoly - Yield Strength - 435 MPa

  • Structural Steel - Yield Strength - 250 MPa

Geometry

  • Note: When Kimberly was working on collision setup, she found that the tube elements weren’t all properly connected

  • Using the Prepare > Beams > Connect feature, it is shown that not all beam elements are connected properly. This may have been fixed when contacts were later applied under ACP (Pre) Model Setup, but efforts will be placed to correct these errors right now.

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  • After modifying the beam elements, number of gaps have greatly reduced

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Model

  • Contacts have been automatically generated for all bodies

    • Contacts are all bonded

    • This can cause error or inaccuracy because this results in contacts being formed between objects that are actually not in contact.

    • FIX: Create automatic connections with specific bodies in mind. Use manual contact regions if necessary.

      • E.g. A separate connection group for gussets, bulkheads

    • Note: I still feel some uncertainty regarding how to fully check that all the correct contacts have been made in a time efficient manner (as opposed to checking every single contact).

      • Soln: check every suspicious tube

      • Double Soln: Run the simulation and check if tubes deform weirdly. If they do, it’s probably because it has been unreasonably contacted.

  • Mesh size: 15 mm

Setup

  • This is the standard stackup for A, B, C bulkheads

  • The fibres in the ModelingGroup.Ply are showing up correctly

Static Structural (B Pillar)

Static Structural Model

See Note below

Static Structural Setup

Static Structural Solution/Results

Static Structural (Side 60)

Static Structural Model

Static Structural Setup

Static Structural Solution/Results

Static Structural (Top 30)

Static Structural Model

Static Structural Setup

Static Structural Solution/Results

Concluding Note:

I have tried to review and edit the simulation file so that it is fixed with better space claim geometry and contacts. The initial goal was to hopefully see that these fixes would improve results and get more accurate solutions.

For some reason, I still have solver pivot error due to an under constrained model on a tube that has so many contacts. This shouldn’t be happening because the tube has been constrained with so many contacts. There is no way for it to fly into space.

At this point, I conclude that it is not worth trying to solve these errors and move onto the next task.

Min’s original simulation is able to compile and have solutions. This means that I will use that file for the next tasks and investigations.

Update:

Asked Min if there existed a compiled solution sims. Unfortunately it somehow got lost.

Back to troubleshooting

Found this resource that taught about this contact tool to check contacts:
A solver pivot warning or error has been detected — Ansys Learning Forum

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Collision Scenario

FEA Meeting (Max S. - MPa)
Chassis Reinforcement Attempt 1 meeting - Mechanical - Confluence (atlassian.net)

New Result (Max S. - MPa)

August 19, 2021

B Pillar

509

445

Side 60

1231

1466

Top 30

1595

1830

2. Review Previous Chassis Simulations

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