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Table of Contents

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  1. Review sheet metal solution FEA that was completed by Min

  2. Review previous Chassis simulations completed by Jason (MS14) and Matt, Shalin (MS12)

  3. Try to insert current sheet metal model into old simulation setups to see if results will change

  4. Investigate sheet metal solution by using a single sheet metal that is similar to BP (bonded to all tubes), but make it out of steel instead of composites

  5. Arrange detailed FEA review meeting with Mech Advisors to discuss steps and next results
    Update team on slack

  6. Reinforcement Rev 2.0

1. Reviewing Sheet Metal Solution FEA

Simulation File Details

Folder Path

D:\Users\Roo\Documents\GrabCAD\MSXIV sims\MS-CHASSIS\Tommy Spring 2021 Reinforcement Sims

File Name

July1_TommyRev.wbpj

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2. Review Previous Chassis Simulations

I don’t think this is worth the time.

Better to focus on current solution

MS14

MS12

3. Inserting Current Solution into Old FEA Setups

I don’t think this is worth the time.

Better to focus on current solution

4. Sheet Metal Inquiry

5. Setup Detailed FEA Review Meeting

Resources

  1. Mech Advisor Contact List - Mechanical - Confluence (atlassian.net)

  2. Facebook group chat

Plan

  1. Looking to finish work deliverables tonight

  2. Look to schedule detailed FEA review meeting for Monday, July 19, or Tuesday, July 20

  3. Send out messages and arrange meeting by end of day Saturday, July 17

    1. Chassis Specialty People: Matt, Shalin, Jason

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I don’t think this is worth the time.

Better to focus on current solution

5. Rev 2.0

Collision Scenario

Stress Results (Max S. - MPa)
Rev 2.0

2 Passenger

B Pillar

478

Side 60

650

Top 30

1667

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I added a reinforcement in the middle to see if it lowers stresses because it would distribute forces more.

It was found that stresses were the same or increased.

It was also found that some scenarios had the reinforcements suppressed for some reason.

Reconsidering how the fixed boundaries and accelerations are done.

I also played around with the masses. Observations based on Top 30. One of our worst cases.

With all masses suppressed, stresses are below 415 MPa (max 350 ish)

If only front 2 passengers is enabled, it reaches like 1000 MPa.

With only battery box enabled, it reaches like 700 MPa.

I believe how we assign the mass is greatly influencing the stresses.
The current geometry assignments for mass are very concentrated.

When we had the bottom panel, the faces on its surface could be used as geometry assignment which distributed the mass vastly.

6. Rev 3.0 - Surfaces for distributed masses

Collision Scenario

Stress Results (Max S. - MPa)
Rev 3.0

All loads

B Pillar

638

Side 60

946

Top 30

2021

All these stresses are higher than the 1.0 setup mentioned in step 1.

It is worth noting that the surface used was 1 inch thickness using foam density meaning there is extra mass.

Although it does seem to prove that surfaces do not have a major effect in reducing stresses.

7. Notes for Later

Stackup of A, B, C Bulkheads for Min’s sheet metal solution FEA
Purpose: Put really thin layers in the explorative FEA (step 4)

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