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Introduction

This page is to quickly take notes of the additional reinforcements added and the stresses observed.

The goal is to reinforce as much as possible until the chassis is under ~200 MPa which is 4130 Chromoly Steel yield strength with a safety factor of 2.

Please take note of:

  • Project file name

  • A quick screenshot

  • Sampled stress results (B Pillar, Side 60, Top 30)

For example,

Scenario

Stress Results (Max S. - MPa)

B Pillar

638

Side 60

946

Top 30

2021

Some previous documentation is found here:
Reviewing Sheet Metal Solution - Mechanical - Confluence (atlassian.net)

But, please continue using this page as documentation for organization purposes.

Note: The latest completed iteration is Rev 3.0

Please start this page with Rev 4.0 and create appropriate saved project files.

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

Rev 4.0 - Fixed Chassis, Applied Force from object

File Name: August22_KL_Rev4.0.wbpj

(Copied from: "July 1_TommyRev.wbpj")

See Rev 4.0 - Fixed Chassis, Accelerating Object for more details.

 Notes:

Goal

  • Previously, we fixed the back face of the collision object and accelerated the chassis into the object. Fixing this face fixes the entire body of the object as it is a single solid body.

  • Rev 4.0 attempts to fix the chassis and accelerate the object into the chassis.

Simulation Set-up

  • The following steps were used to set up the simulations (see sub-page for more details)

    • Suppress existing 5G acceleration

    • Suppress the existing fixed support on the collision object

    • Add new fixed support to the chassis

    • Add the equivalent force

    • Add displacement constraints to control the motion of the collision object if needed

Conclusions

  • stress results can change drastically depending on the fixed supports selected (much higher or much lower)

  • This setup can be used to our advantage to obtain lower stresses however, we will need to justify the fixed supports we choose.

  • Overall, it might be best to stick with the fixed object setup to avoid ambiguities or any issues getting the VDR approved.

Stress Results

Max Combined Stress (MPa)

Scenario

Fixed Object

Fixed Chassis

B-Pillar

351.49

304.86

Side 60

648.65

1226.8

Top 30

1374.9

1667.6

Rev 5.0 - Longitudinal Reinforcements

File Name: August23_KL_Rev5.0.wbpj

(Copied from: "July 1_TommyRev.wbpj")

Notes:

  • Focused on lowering stresses for Top 30 wall case

  • Added a total of 12 longitudinal reinforcement tubes to try to add more resistance to bending during impact

    • all 1” square tubing

    • Testing the effects of a greater wall thickness (0.113”)

  • Note: there are currently interferences with floor panels, changes can be made to the reinforcement placement later

Stress Results

(not done yet, running into errors - some tubes were split into tiny segments?)

Max Combined Stress (MPa)

Scenario

REV 2.0/3.0?

("July 1_TommyRev.wbpj")

REV5.0

B-Pillar

351.49

to do

Side 60

648.65

to do

Top 30

1374.9

to do

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