e-light, Work Package 4,
Structural Dynamics Study
Ivan Grajciar Senior CAE Engineer,
Ricardo UK
17-20 November 2013
EVS27 Barcelona
GA No: 266284
e-light, BIW, CAE Study
WP4 Objective: CAE work conducted by Ricardo
To assess the behavior of BIW of e-light structure from static and dynamic
performance point of view, to achieve class leading stiffness, durability and
NVH performance while optimising the mass of CFRP components
Crash assessments were also made to validate the design, however these
were conducted by Cidaut
e-light, BIW, CAE Study
Story of the design of e-light body structure – process overview
Pininfarina Nido Concept Nido size and package study Target definition from resized Nido
Initial e-light design Structural Optimisation
e-light concept exploration CAE Parametric model
Optimised CFRP structure Design update
e-light, BIW, CAE Study
Nido package and size study
Roof line increased to achieve
head clearance with re-
positioned driver
Hardpoints and a surface
definition for e-light
Side impact barrier
H-point move also enabled
Driver H-point and b-pillar moved side impact barrier to contact
forwards to accomodate e-light
a-pillar
requirement for 2+2 passengers
e-light, BIW, CAE Study
Definition of e-light structural targets from resized Nido
The Nido resized Model was benchmarked for all assessments
Static torsional and bending stiffness
First torsional modal frequency as a target for dynamic stiffness
Torsional stiffness Bending stiffness Modes
e-light structural performance targets
11.5kN/mm 8.8kN/mm 43.3Hz
e-light, BIW, CAE Study
e-light concept established through brainstorming and selection process
A) Door Ring C) Half Monocoque D) Open Ring F) Cage
E) B-Pilar
G) Tubes
Concept selection matrix
e-light, BIW, CAE Study
Novel optimisation approach based on parametrically defined FE-model
using software SFE Concept
Geometry optimised for cross-section shape, thickness and ply fibre orientation
simultaneously
Objective to minimise mass and meet stiffness requirements
Automatic update of CAE model after each optimization run
2. Definition of
design variables
e-light, BIW, CAE Study
Definition of design variables for optimisation
Parametric model defined to allow panel shape, size, position and section control
Entire e-light baseline model defined with parametric variables
SFE Concept, Official Demo
(Copyright © 2013 SFE GmbH)
Bracket-post
example
e-light, BIW, Parametric Model
e-light Door ring
example
e-light, BIW, CAE Study
Summary of optimisation output
Change of cross sections (CS) combined with change of thickness
(TH) of main components after numerical optimization
Ply thickness and orientation output shown for one panel
Example of result for top face of
front cross-member
Top Middle Crossmember:
CS: +60% TH=4.7mm
Top Rear Crossmember:
TH: 3mm -> 4.5mm TH=4.8mm
CS: +35%
Top Fr. Crossmember: TH: 1mm -> 3mm
CS: +40%
TH: 1mm -> 3mm
TH=3.4mm TH=1.0mm
Thickness Fibers
Layer Thickness Fibers
Optim.[mm Optim.
no. Initial [mm] [DEG]
] [DEG]
1 0.25 0.6 ≡≡≡ 0° ° 3
A-Pillar:
2 0.25 0.54 °
////// 45° 30
CS: -10%
3 0.25 0.06 °
|||||| 90° 105
TH: 3mm -> 4.5mm
C-Pillar: 4 0.25 0.54 °
\\\\\\ -45° -30
CS: +150% 5 0.25 0.06 |||||| -75
6 0.25 0.6 ≡≡≡ 3
TH: 2mm -> 3mm
7 0.25 0.6 ≡≡≡ 3
8 0.25 0.06 |||||| -105
B-Pillar: 9 0.25 0.54 \\\\\\ -30
CS: -10% 10 0.25 0.06 |||||| 105
TH: 3mm -> 3mm 11 0.25 0.54 ////// 30
12 0.25 0.6 ≡≡≡ 3
Total 3.0 4.7 N/A N/A
[ Grey Colour= Initial Cross Section ]
e-light, BIW, CAE Study
Structural performance of optimized CFRP E-light structure
The final model was validated for all assessments
Static and dynamic stiffness of E-light structure increased
Inertance and VTF’s generally consistent with benchmark model Nido
Durability performance acceptable
Stiffness: static bending and torsional Durability: body loads applied to VTFs: wheel to cabin panel response assessed
and first torsional mode assess durability of lamina & bonding to understand likely interior noise
e-light structural performance generally better in comparison to benchmark Nido
Stiffness:
- bending G increase 7% Failure index <<1.0 Generally consistent with
- torsion G increase 12% benchmark model
- 1st frequency Gincrease 4%
e-light, BIW, CAE Study
Summary of results
Parametric optimized
32% reduction in mass
Parametric Initial
Improved static stiffness and modal performance
Nido Resized,
Durability performance maintained, worst case result in
interlaminar bonding gives good safety factor of 3.6
Targets
e-light
e-light
VTF results show lower overall responses in key panels
indicating lower noise radiation into cabin
Mass
Bending
Stiffness Stiffness
Mass 1st Torsional
Bending Torsion
[kg] Mode [Hz]
[kN/mm] [kNm/DEG]
Torsional
Stiffness
Nido Pininfarina
140.4 8.8 11.5 43.3
(Al-Baseline, Target)
e-light Parametric 99.6 8.1 8.6 42.8
( THs initial) ( -40% ) (-8.6%) (-33.7%) (-1.1%) Modal
e-light Parametric 106.1 9.4 12.1 45.0 Frequency
( THs optimized) ( -32% ) (+6.7%) (+5.2%) (+3.9%)
CAE step in time
e-light, BIW, CAE Study
Conclusion
A novel approach has been demonstrated to optimising CFRP lightweight body
structures
The approach has delivered an attractive 32% weight saving through only
optimizing the CFRP part of the BIW structure.
Body structural performance generally improved
e-light, BIW, CAE Study
THANK YOU FOR
YOUR ATTENTION
