Modeling and simulation for large scale production systems

Computer modeling and simulation provide a foundation upon which industrial processes and systems can be transformed and innovation dramatically accelerated. Computer modeling and simulation is also an indispensable tool of the information age, used extensively in design, analysis, operations, decision-making, optimization, and education and training. Manufacturing, production and design relies upon simulation to develop efficient production systems and factories that produce quality products. Simulation in industry has yet to meet its full potential. The development of models is very time consuming, particularly for geometries of complex engineering systems such as manufacturing plants, automobiles, aircraft and ships. Computer simulation allows scientists and engineers to understand and predict three-dimensional and time-dependent phenomena in science and engineering discipline. This talk will focus on challenges associated with modeling and simulation in the manufacturing sector and through a number of case studies highlight the benefits gained through the use of such technologies.

Experimental stress analysis of a steel light truck wheel

The development of a new automotive wheel requires extensive testing and possible design changes. The wheel investigated had three major changes during development. These three designs were subjected to a stress analysis, by experimental methods, to allow a comparison to be made between each design. The experimental program tested the wheels under conditions designed to simulate the loading of the front wheels whilst cornering. A loading frame was built for this purpose and all testing was performed statically by multiple loading for different directions of bending moment. Brittle lacquer coatings were used on each wheel to highlight high strain areas and indicate optimum locations for the placement of strain gauges. The strain gauges were then used to evaluate the strains. Wheel stud loads were also monitored via strain gauges applied to two of the wheel studs. All data was stored on magnetic tapes and the stress analysis performed by means of a minicomputer. The results of the stress analysis showed quantitatively the improvement in design from the first to the third wheel design. The analysis of the stud loads and their variation during loading indicated the optimum wheel mounting face geometry to ensure nut loosening would not occur in service.

Controller area network (CAN) modelling for automotive body control applications

This research details methods to improve upon current worst-case message response time analysis of CAN networks. Also, through the development of a CAN network model, and using modern simulation software, methods were shown to provide more realistic analyses of both sporadic and periodic messages on CAN networks prior to implementation.

Testing and modelling to obtain material behaviour for crash simulations

The thesis focusses on improving the material behaviour models used in vehicle crash simulations by identifying the mechanical properties most important to crash events, reformulating the material models used in crash simulations, and developing new tests to obtain crash-relevant material.

Investigation on the forming behaviour of metal/polymer laminates

A metal/polymer laminate is a new light weight sheet material suitable to replace conventional steel or aluminium sheet in future car designs. In this study the effect of material composition and process conditions on the forming behaviour of metal/polymer laminates in sheet metal forming was investigated by experimental, analytical and numerical methods.

Composite crashworthy structures

This study presents an innovative finite element delamination model which successfully reproduced the experimental failure behaviour observed in axial crush testing. Tests were conducted on tubes manufactured by a novel composite curing process, resulting in the ability to cure tubular profiles in 7 minutes - 95% quicker than traditional autoclave curing.

Structured methodology for evaluating stamping feasibility of new part design

With the introduction of ultra high strength materials and new forming techniques the feasibility process to produce a manufacturable component is extremely difficult. The aim of this thesis was to develop a set of 'design windows' and 'guidelines' for designers and stamping engineers to reference in the initial design phase.

Cracking and distortion of water jackets in engine blocks

This thesis investigated the cracking and distortion of water jackets in engine blocks. The Taguchi method was utilized to improve production process and in doing so, reducing the scrap of water jacket cores by over 60%. Further, by altering core material and pouring temperature, casting distortion was improved.

Surface analysis of carbon fibre epoxy composites

This thesis investigated the surface finish of rapidly cured composites for automotive body panels. Findings showed that curing composites with rapid heating rates increased surface roughness, although it improved paint adhesion to the substrate. This thesis also highlighted the need for surface barriers to reduce fibre print through during aging.

Vehicle design for minimum societal harm

A design technique was developed to provide the best protection to all occupants in the real-world crashes that occur on Australian roads. A team of experts from around the world was marshalled to analyse crash data, develop new information on impact injury and a new computer optimising technique for simulation of side impact crashes.

CAE crash analysis of structures in oblique loading

This work focussed on how tubular steel structures similar to that in frontal car frames deform under crash conditions. The novelty comes from finding three crash modes: axial crush, transitional and global bending. Each mode was categorised by reaction force and energy absorption, this allowing for better structural design practices.

Adaptive intelligent systems for energy management of vehicles

The thesis demonstrated the architecture of adaptive intelligent systems for energy management that is capable of interacting with complex systems including the vehicle, environment, and driver components, as well as the interrelationships between these variables, to deliver fuel consumption improvements.

Development of novel crash structures

In this thesis, the crash properties of carbon fibre composites were studied in detail. Also, novel materials were developed and characterized so that they could potentially be used for automotive crash applications.

Springback investigation in roll forming of a V-section

To have fuel efficient vehicles with a lightweight structure, the use of High Strength Steels (HSS) and Advanced High Strength Steels (AHSS) in the body of automobiles is increasing. Roll forming is used widely to form AHSS materials. Roll forming is a continuous process in which a flat strip is shaped to the desired profile by passing through numerous sets of rolls. Formability and springback are two major concerns in the roll forming of AHSS materials. Previous studies have shown that the elastic modulus (Young's modulus) of AHSS materials can change when the material undergoes plastic deformation and the main goal of this study is to numerically investigate the effect of a change in elastic modulus during forming on springback in roll forming. Experimental loading-unloading tests have been performed to obtain the material properties of TRIP 700 steel and incorporate those in the material model used in the numerical simulation of the roll forming process. The finite element simulations were carried out using MSC-Marc and two different element types, a shell element and a solid-shell element, were investigated. The results show that the elastic modulus diminution due to plastic strain increases the springback angle by about 60% in the simple V-section roll forming analyzed in this study. © (2014) Trans Tech Publications, Switzerland.