MSC Software Corporation

While Sheet Molded Compound (SMC) materials have been widely used in the automotive industry for some time, recently there has been a move to apply SMCs on more structurally demanding components. Though the material has long been considered quasi-isotropic with relative success, it has become apparent in industry that due to the complex manufacturing process, optimal structural design is not possible without considering the real anisotropic nature of the material.. With growing demand from the market, now is the time to leverage advanced SMC modeling capabilities targeting crash performance.

Static and crash FEA simulations can now attain an excellent level of accuracy in stiffness and can capture peak load and displacement trends for typical part load cases.

The inner seat part illustrates the proposed workflow from process simulation to structural application. The Digimat simulation achieves a much better fit with respect to test data for most load cases, including head impact (puncture) and provide a good indication of hot spot localizations.

Avoid additive manufacturing issues (distortion, residual stress) and establish a “right first time” manufacturing process.

Build process simulation helped Bosch to predict manufacturing issues and to find the right countermeasures to optimize the AM build process.

Zuura Formula Racing is a student team from the Vellore Institute of Technology in Chennai, India that participates regularly in the Formula SAE student competition organized across the globe by SAE Interna-tional.

For participating teams, the task at hand is to develop a small formula-style race car. Each student team designs, builds and tests a prototype based on a series of rules, aimed at ensuring on-track safety and promoting clever problem solving. The prototype is evaluated for its potential as a production item.

During the course of this project, one of the focus areas for the Zuura Formula Racing team was to ensure good suspension for their vehicle. To achieve this, they needed to ensure that the tires were as perpendicu-lar to the ground as possible to achieve maximum traction. The front geometry had to be designed such that it had a negative camber in jounce. This was an important factor in keeping the wheels perpendicular to the ground, and also to resist body roll.

The main target before the vehicle dynamics simulation engineer at Zuura Formula Racing was to improve the ride and handling of the vehicle by reducing yaw, pitch and roll rates.

The Zuura Formula Racing team used the Adams Car software from MSC Software. Adams Car allows students to design and simulate their FSAE vehicles to maximize their vehicle performance. With Adams Car, FSAE teams can quickly build and test their functional virtual prototypes of complete vehicles and vehicle subsystems. FSAE engineering teams can exercise their vehicle designs under various road condi-tions, performing the same tests they normally run in a test lab or on a test track, but in a fraction of time.

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