Logistics Information

Conducted By	Tommy Tran
Date	2021-07-16

Quick Links

Chassis Reinforcement Attempt 1 meeting - Mechanical - Confluence (atlassian.net)

https://docs.google.com/document/d/1B2brtRLK9Q83bQ87CmbALqR1k8uJYuV-0p5O8A_-x6Q/edit

https://docs.google.com/presentation/d/1QQaFrP_eXH-VLmBz8twwj8uvzSL7mxke4xi0hvFKOWw/edit#slide=id.ge4b8a20e23_0_27

Working Session Goals

Review sheet metal solution FEA that was completed by Min
Review previous Chassis simulations completed by Jason (MS14) and Matt, Shalin (MS12)
Try to insert current sheet metal model into old simulation setups to see if results will change
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
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 Reinforcement Sims
File Name	July1_TommyRev.wbpj

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

Collision Scenario

FEA Meeting (Max S. - MPa)
Link

New Result (Max S. - MPa)

August 21, 2021

2 Passenger (Max S. - MPa)

August 21, 2021

B Pillar

509

407

351

Side 60

1231

829

648

Top 30

1595

1700

1374

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

I don’t think this is worth the time.

Better to focus on current solution

5. Rev 2.0

Collision Scenario

FEA Meeting (Max S. - MPa)
Rev 2.0

2 Passenger

B Pillar

478

Side 60

650

Top 30

1667

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.

6. 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)