ARMY VEHICLE DURABILITY OPTIMIZATION & RELIABILITY

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1 Right Track Left Track ARMY VEHICLE DURABILITY OPTIMIZATION & RELIABILITY Solid Modeling Dynamic Load Analysis kkchoi@engineering.uiowa.edu Pro/E Terrain Model Displacement - Inches Test Course Microprofile ATC Cross Country 3 Course - Left and Right Tracks November, 1998 De-trended Data System Model Dynamics Analysis DADS Distance - Feet of Road Profile DRAW ANSYS NASTRAN Component Stress Analysis FE Model Dynamic Stress Durability Analysis and Reliability-Based Design Optimization Fatigue Life Refined Fatigue Analysis RBDO/PBDO Contour DP3 DP1 DP2 DP5 DP4 DRAW Fatigue Material Properties DSO RBDO/PBDO of Material Properties of Geometry & Dimensions How to Optimize the Vehicle Design to Minimize/Reduce the Weight? Under These Uncertainties, How to Achieve Component Level Reliability? Under These Uncertainties, How to Achieve System Level Reliability?

2 DESIGN OPTIMIZATION UNDER UNCERTAINTY Reliability-Based Design Optimization (RBDO) Possibility-Based Design Optimization (PBDO) Mixed Variable Design Optimization (MVDO) Robust Design Optimization (RDO) Input Data Analysis Optimization Design Aleatory Uncertainty Epistemic Uncertainty Reliability Analysis: HMV+ Analysis for MVDO MFS Possibility Analysis: MPS RBDO MVDO PBDO Optimum Design with Low Failure Rate Uncertainties of System Input Probability of System Failure Optimum Design for 6-Sigma Deterministic Optimum Design - Not Reliable RBDO Optimum Failure Surface Design with g 1 (X)=0 Desired Reliability X 2 Input Joint PDF Contour Initial Feasible Failure Surface Design g 2 (X)=0 0 X 1

3 PLAN OF RELIABILITY RESEARCH, APPLICATION, AND TECHNOLOGY TRANSFER IN CAR&D Present Future Center of Automotive Reliability & Design (CAR&D) Reliability Assessment and Optimization Data Modeling Structures and Design Multiscale & Multilevel Analysis & Design Micromechanics and Materials Prognosis and Condition Monitoring Manufacturing Processes Multibody Dynamics Testing and Validation Basic Research Funded by TACOM through ARC: DRAW, DSO & RBDOT Methodology and Software Tools, NVH DSA & Optimization Application of CAR&D developed M&S and T&V technologies to Army FCS for Weight Reduction Initiative with High Reliability Application of DRAW, DSO & RBDOT to Army Stryker for Weight Reduction Initiative with Durability and High Reliability Demonstration of DRAW, DSO, and RBDO using Army HPC for Fatigue Life and Reliability improvements for HMMVW Future CAR&D Developed M&S Tools and T&V Methods for Technology Transfer Low and High Frequency NVH DSA and Optimization Software Tools DRAW, DSO, RBDOT, and Reliability Analysis Software Tools Research Case Studies for Validation Tech Transfer

4 NOISE, VIBRATION, & HARSHNESS DESIGN OPTIMIZATION (FEA-BEA & EFEA-EBEA) Structural Model NASTRAN Frequency Response Analysis [jωm + κk]{v} = {f} 1 Nodal Velocity COMET Boundary Element Analysis [A]{p S } = [B]{v} p = {b} T {v} + {e} T {p S } 2 NASTRAN Input Load Acoustic Pressure NASTRAN Frequency Response Analysis [jωm+κk]{λ * }={F} (UM Code) 3 Adjoint Variable DSO Sensitivity Analysis Program * ψ v, λ = l λ jωd v, λ κa v, λ * * * ( ) δu ( ) δu ( ) δu ( ) Pressure Sensitivity p / u DOT Optimization Program Design Parameters, Objective Function, Constraints Optimized? No Update Model Yes END

5 STAMPING & METAL FROMING PROCESS DESIGN USING MESHFREE METHOD Development of Design Sensitivity Analysis (DSA) and Optimization Capability of A Seamless Integration of CAD-Simulation-Design Large Shape Changing Problems without Remodeling Finite Deformation Elastoplasticity for Manufacturing Process Design Frictional Contact Problems for Die Shape Design Optimization Nonlinear Shell DSA for Sheet Metal Stamping Process Design Extrusion Design Optimum Design Gasket Design Pressure Distribution Stamping Design FEA Took 58 Iterations* with 7 Remodelings Meshfree Took 17 Iterations w/o Any Remodeling