BPILLAR REDESIGN
Submitted by:
Gurushish Singh Grover
5331622
M10MAECOMPUTERAIDEDENGINEERINGBPILLARREDESIGN
Table of Contents
ListofFigures.............................................................................................................................2
ListofTables..............................................................................................................................3
ExecutiveSummary...................................................................................................................4
1.
Introduction.......................................................................................................................5
2.
ProblemStatement...........................................................................................................6
3.
LiteratureReview..............................................................................................................7
3.1.FiniteElementAnalysis(FEA):........................................................................................7
3.2.LoadCaseStudy:.............................................................................................................8
3.3.Meshing..........................................................................................................................9
3.3.1.MeshingSize............................................................................................................9
3.4.EuroNCAP....................................................................................................................10
4.DesignModification.............................................................................................................11
4.1.DesignParameters........................................................................................................11
4.1.1.SecondMomentofArea.......................................................................................11
4.1.2.Material.................................................................................................................12
4.1.3.Weight...................................................................................................................12
4.2.Design...........................................................................................................................12
5.ModelAnalysis.....................................................................................................................13
5.1.Procedure.....................................................................................................................13
5.2.Analysis.........................................................................................................................14
5.3.Discussion.....................................................................................................................14
6.2DCADDrawings.................................................................................................................15
7.ConclusionandRecommendation.......................................................................................19
8.Bibliography.........................................................................................................................20
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List of Figures
Figure1:BPillarStructure(AltairEngineering).......................................................................5
Figure2:InitialAnalysis.............................................................................................................6
Figure3:LoadCase....................................................................................................................8
Figure4:SideCrashTest.........................................................................................................10
Figure5:HatSection(Anoop,2009).......................................................................................11
Figure6:Reinforcement..........................................................................................................12
Figure7:Assembly...................................................................................................................13
Figure8:VonMisesStressandDisplacementonAssembly...................................................14
Figure9:BPillarDraft.............................................................................................................15
Figure10:ReinforcementDraft...............................................................................................16
Figure11:ExplodedDraft........................................................................................................17
Figure12:AssemblyDraft.......................................................................................................18
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List of Tables
Table1:MaterialRestrictions...................................................................................................6
Table2:MeshResults................................................................................................................9
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Executive Summary
ThereportisabouttheprojectforredesignoftheBpillarbyaddingreinforcement.The
reportdealswiththedesignandanalysispartofthepillar.Itdiscussesvarioustoolsusedfor
theanalysislikeVonMisesStresses,displacement,etc.Thereportexplainsthedetailsabout
thecontentsrequiredforproperanalysisofthesystemlikeMeshsize,factorofsafety,etc.
ExamplesofotherprojectssimilartotheBpillararealsodiscussed.Theprocedureofthe
designingandanalysiswithrelevantfiguresareshowninthereport.Theforcesappliedon
theBpillarandtheeffectonitandtheresultsarealsodiscussed.Thedifferentparameters
thataffecttheperformanceandstrengthofthepillararealsocommented.
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1. Introduction
TheBpillaristhestructurelocatedbetweenthefrontandreardoorsofthevehicle.Therole
ofthepillarisnotonlytosupportthestructurebutitplaysvitalroleinsidecrashesandroll
overs,helpinginlessdamagetothepeopleinsideit.StructureofBpillarisshowninfig.1
Intheproject,Bpillarwasprovidedandtheobjectivewastostrengthenthepillarforthe
safetyofthepassengers.Ouraimwastofirstanalysethegivenpillarandnotethestresses
anditsdisplacementactingonitwiththehelpofforcesandafterthatredesignthepillarby
addingreinforcementandthenanalysingitagaintodecreasethestressesandthe
displacements.TheBpillartobedesignedwillhavetosustainsideimpactstaticloadof
140KNinYdirection.
Figure1:BPillarStructure(AltairEngineering)
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2. Problem Statement
ThematerialoftheBpillarwasgivenandallthepropertieslikedensity,yieldstrength,
youngsmodulus,etc.forthematerialwasgiven.Theanalysisofthepillarwasperformed
firsttocheckthestressesandtheinitialdisplacementofthepillarataforceof14KN.
Figure2:InitialAnalysis
BPillar
1.4
CPSteel800/1000
7850
210
800
1000
Reinforcement
2.0
HighAlloySteel
7850
210
1500
1700
Poisons
ratio
Material
Tensile
Strength
(MPa)
Maximu
m
Thickne
ss(mm)
Youngs
Modulus
(GPa)
Yield
Strength
(MPa)
Component
Density
(Kg/m3)
ThefigureaboveshowsthedisplacementandtheVonMisesstressontheBpillar.Thispillar
neededtoberedesignedtodecreasethedisplacementandthestresswhosemaximumlimit
weregiven.Thematerialforthereinforcementwasalsogivenwithitspropertieslike
density,yieldstrength,etc.TablebelowshowsthedescriptionoftheBpillarand
reinforcementsmaterialandmechanicalproperties.
0.3
00
0.3
00
Table1:MaterialRestrictions
Themaximumdisplacementallowedwas40mmandmaximumstress800MPaforthere
designedBPillar.
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3. Literature Review
FiniteElementAnalysisisanumericalprocedureinwhichallthecomplicationsofthe
problemaremaintainedsameandapproximatesolutionsareobtained.Displacementand
stressareconsideredtobeimportantFieldVariablesofsolidmechanicsinFEA.(Gupta,
2003).
Inacontinuum,FieldVariablesareinfinite.Theseinfinitevariablesarereducedtofinite
numberbydividingregionintoelementsandexpressingtheunknownfieldvariablesas
approximatingfunctions.Theseapproximatingfunctionsarecallednodalpointsornodes.
SotheunknownarethefieldvariablesofthenodesinFEA.
Nextstepistoassembleelementpropertiesforeachelement.Forexample,mathematically
wecanfindtherelationshipbetweenstiffnesscharacteristicsofeachindividualelement.
[k]e{}e={F}e
Where,
[k]e=ElementStiffnessMatrix,
{}e=NodalDisplacementVector,and
{F}e=NodalForceVector
Toassemblestructureproperty,elementpropertiesareused.Afterthisstep,theboundary
conditionsaredefined.(Bhavikatti,2005)
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TheloadsusedinthisprojectareSideImpactstaticloadswhichissimilartothecrashtest
analysisbysafetyregulations.
Theassemblyisfixedat18pointsi.e.9onupperandlowerendseachtoassumethatitis
attachedtothevehicle.Aloadof140KNisappliedonthetopsurfaceofthepillarasshown
infigurebelow.
Figure3:LoadCase
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3.3. Meshing
AsignificantstepoftheFEAmethodismeshgeneration.Meshingistheprocessofdividinga
givenbodyintosmallelements.Meshingcanbecharacterisedon3differenttypes:
1.StructuredMesh
2.UnstructuredMesh
3.HybridMesh
Structuredmeshisidentifiedbyregularconnectivity.Elementshavegeometricalproperties
oforderedgrid.Theseareeasytocomputeandrequirelesstimeandmoreelements
whereasunstructuredcontaintrigulationandquadteesofpointsets.Hybridmeshis
combinationalofstructuredandunstructuredmeshing.Thereisalsoamanualmeshtypes,
knownasfreeandmappedmesh,wherethetypeofmeshismentionedbeforestartingthe
analysis.(O.C.Zienkiewicz,2005).
TheanalysisoftheinitialBpillarwascarriedoutwithdifferentmeshsizes,andrespective
displacementsandthestresseswerenoted.Andameshsizewasselectedthatwouldbe
appliedagainontheredesignedBPillar.Thetablebelowshowsallthereadingsbetween
meshsizes215.Thehigherthemeshsize,thelesstimeittakestogetresultsoftheanalysis
buttheaccuracyoftheresultdecreasesandviceversa.Sochosemeshsizeof5becauseits
notfineandnottoolargeandtimeforanalysiswillnottaketoomuchtimeascomparedto
meshsize2andtheaccuracywillbegood,ifcomparedwithhighermeshsize.
Mesh size
Displacement
(mm)
Stress (MPa)
15
14
12
10
9
8
7
6
5
4
3
2
47.8
51.1
50.3
47.6
45.8
48.2
50.1
50.4
49.4
50.3
49.6
50.8
8.47*E03
7.19*E03
8.28*E03
8.32*E03
9.35*E03
9.61*E03
1.11*E04
1.09*E04
1.01*E04
1.12*E04
1.25*E04
1.35*E04
Table2:MeshResults
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EuroNCAPistheEuropeannewcarassessmentprogrammewhichorganizescrashtestsand
passesontheresultstotheownerofthevehiclewiththeassessmentofthesafety
performanceofthevehicleforimpactsofthevehicleatrealisticinstanceforces.Thereare
basicallytwoimpactassessmentsthatarecarriedout,1.Frontcrashtestand2.Sidecrash
test.Figureofsidecrashtestisshownbelow.(EuroNCAp)
Figure4:SideCrashTest
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4. Design Modification
AfterapplyingforcesontheinitialBpillaranditsanalysis,itisobservedthatdisplacement
ofthepillarismorethan40mmandthestressdistributionisnotuniform.Insomeareas,
thestressismorethantheyieldstrengthofthepillarmaterial,sofactorofsafetycannotbe
consideredfortheinitialpillar.So,toimprovethis,reinforcementshouldbeaddedtotheB
pillartoreducethedisplacementandtohaveuniformstressdistributionwithmaximum
stressbelow800Mpaonthepillar.
Secondmomentofareaisdefinedasgeometricpropertyofaparticularareathatwillreflect
howpointsonthisareaaredispersedonarandomaxis.Itisalsocalledasmomentofinertia
onaplaneareaandareamomentofinertia.
ThecrosssectionoftheBpillarcanbeconsideredashatsection,astheshapeisalmost
similar.Stressdistributionacrosshatsectioncanbeseeninfigure5.
Figure5:HatSection(Anoop,2009)
Thesecondmomentofinertiaforhatsection:
2
Ifwetrytominimizethedeflectionbyincreasingthethicknessofthesection,theweightwill
increase.Sothereinforcementplatewithhatsectionispreferable.
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4.1.2. Material
Thestressesaredependentonthepropertiesofthematerial.Thedimensionalstructureof
theBpillarcannotbechanged,soareinforcementofalightermaterialwithhighyield
strengthisrequiredtosupportthepillar.SothematerialforthereinforcementisHighAlloy
Steelthatisnormallyusedfortheseapplications.
4.1.3. Weight
ThemaximumweightallowedforredesigningoftheBPillaris5kgandtheweightofthe
pillarwithoutreinforcementis2.4kg,sothereisalimitationofweightforthe
reinforcement.Therefore,thereinforcementshouldbedesignedatplaceswherethe
stressesaremaximum,sothestressdistributionwillbeuniformandthestructurewontfail.
4.2. Design
ThereinforcementisdesignedasarectangularmodelwhichwillbeweldedtotheBpillar.
Thisreinforcementwillhelpinreducingthestressdistributiononthecentralsurfacesofthe
Bpillarwherethestressconcentrationswillbehigh.TherewerenochangesmadetotheB
pillar.Figure6showsthereinforcement.
Figure6:Reinforcement
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5. Model Analysis
5.1. Procedure
ThereinforcementisnowassembledwiththeBpillarandnowitisreadyfortheanalysis.
ThisassemblyisnowtransferredtoGenerativeStructuralAnalysis.Materialsspecifiedinthe
projectdefinitionaredefinedtothebpillarandthereinforcement.Theanalysisforthe
resignedpillarissameastheearlieronei.e.triangularmeshwithparabolicelementis
appliedontheelementsoftheassembly.
Propertiesofthematerialsaredefinedtotheassembly.Thethicknessofthereinforcement
isgivenas2mmthatwasthemaximumlimitallowedfordesigningthereinforcement.Line
contactisusedfortheconnectionsoftheassemblyastherewasnopointcontactbetween
thesurfaces.Seamweldingusedtojointhesurfacesofthepillarandreinforcementby
bindingtechnique.Alltherestraintswerefirstappliedontheassemblyasearlierandthen
theforceswereapplied.Figure7showstheassemblyoftheBpillarandthereinforcement.
Figure7:Assembly
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5.2. Analysis
RedesigningtheBpillarwithreinforcementreducedthedisplacementofthepillarbyagreat
value.Thedisplacementofthepillarreducedfrom50mmtoalmost22mm.Thestresseson
theassemblyhavealsoreducedalotbutatthecurvesandtheendofthebpillarthereare
stillsomehighstressareas.
Figure8showstheVonMisesStressanddisplacementoftheredesignedBpillar.
Figure8:VonMisesStressandDisplacementonAssembly
5.3. Discussion
Lighterandstrongermateriallikecarbonsteelcanbeusedtoreinforce,sothatwilldecrease
theweightwhileincreasingthestrengthofpillar.Andthereinforcementcanalsobegivento
theedgesofthepillar,sotherewillbenohighstresspointsinthestructure.
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Alltheanalysishasbeendoneandtheresultswererecorded.Buttheproblemwiththe
stressdistributionstillnotsolvedneartheendsofthepillars.Learntsomenewtechniques
fortheanalysisinCATIA.
Istillrecommendchangingthematerial,whichwillaffecttheanalysisandreducethe
stressesandthedisplacement.Andtherewillbelessornopointsoffailureordistributionof
stresseswillbeeven.
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8. Bibliography
AltairEngineering.(n.d.).Retrieved2009,from
http://altairatc.com/europe/Presentations_2009/Session_15/VOLKSWAGEN_
091104_VWAG_EHTC2009.pdf
Anoop,C.(2009).FundamentalsandPreliminarysizingofsectionsandjoints.Delhi.
Bhavikatti,S.S.(2005).FiniteElementAnalysis.NewAgeInternational.
EuroNCAp.(n.d.).Retrievedfromhttp://www.euroncap.com/about.aspx
Gupta,K.(2003).FiniteElementMultidisciplinaryAnalysis.AIAA.
O.C.Zienkiewicz,R.T.(2005).TheFiniteElementmethod:ItsBasisand
Fundamentals.ElsevierButterworthHeinemann.
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