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Automotive

FEXILON supports varied types of CAE analysis for Automotive domains that include:

  • All types of Static, Dynamic, Linear & Non-linear simulations
  • Durability simulations
  • Vehicle dynamics & stability
  • Rollover simulations
  • Assembly Optimization i.e. weight-reduction & strength-enhancement
  • Sheet metal forming simulations
  • Crash, Impact & Drop-test simulations

We provide the CAE Analysis / Validation support for the following Automotive systems:

  • Chassis and Suspension
  • Powertrain
  • Underbody Components
  • BIW
  • Metal to Plastics Conversion
  • Ergonomic Systems
  • Packaging
  • Vehicle Integration





Optimization of a Gear-shifting Housing

Summary

  • Generation of optimal design for stress, manufacturability, functionality and cost
  • Input – Rough concept

Key Challenges

  • Limited packaging space
  • Manufacturability of the complex ribs and walls

Accomplishments

  • Mesh Generated using Hypermesh
  • Design optimized for weight using Optistruct
  • Reduced stress levels
  • Optimized the design with reduced weight and increased rigidity by providing      adequate ribs.
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Optimization of the Chassis of a Truck

Summary

  • Generation of optimal strength and rigidity.
  • Input – Rough concept

Key Challenges

  • Short Lead-time
  • Connectivity of different components of the assembly

Accomplishments

  • Mid-surfaces were extracted and 2D mesh was generated in Hypermesh. Stress   analysis was carried out for various loading conditions and the design was      optimized for weight using Optistruct.
  • Design optimized for weight using Optistruct
  • Optimized the design of Chassis was achieved with reduced weight and increased      rigidity.
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Stress Analysis of Output-shaft

Summary

  • To simulate the stress-distribution & estimate fatigue-life of the Output-shaft of Gear Reduction Starter (GRS) motor assembly
  • Input – 3D Model

Key Challenges

  • Model clean-up
  • A lot of very-small features obscuring FE Modeling
  • Helical gear-teeth increasing complexity

Accomplishments

  • Unstructured 2nd Order Mesh Generated
  • Appropriate BCs enforced and Analysis Performed
  • Critical regions identified
  • Design optimized to achieve desired Fatigue life
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Stress Analysis of Annulus

Problem

  • To estimate the stress-levels on the Annulus of Gear Reduction Starter (GRS) motor assembly
  • Input – 3D Model & loading conditions

Solution

  • Unstructured 2nd Order Mesh Generated
  • 10-noded tetra elements used
  • BCs extracted from assembly
  • Optimized the design for strength
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Buckling load estimation of a conical shell-structure

Problem

  • To estimate the maximum Buckling load-carrying capacity of a conical shell-structure.

Solution

  • Structure modelled with 2D Shell elements.
  • Support specified at lower-rim.
  • Fixed translation in radial and hoop.
  • Arrested rotation about hoop
  • Axial load applied at the other rim with a sinusoidal distribution
  • Buckling deformation and stress-field established as per client requirements.
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