Centre for Automotive Technology (CAT) School of Applied Science. Sustainable Automotive Solutions

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1 Centre for Automotive Technology (CAT) School of Applied Science Sustainable Automotive Solutions Professor Kambiz Kayvantash

2 A global approach Energy Safety Interactions Manufacturing Service Recycling Function -> Transport humans and goods Mass Energy Speed Constraint -> Preserve both safety Performance Low Carbon G = Crashworthiness and Safety (m,dv) Vehicle Life Cycle 10% 80% 10% Cost-benefit Manufacturing Field Testing (road, terrain, tyre, environment, infrastructure), measurements F= Energy consumption (V) Lightweight Physical and Virtual Testing Manufacturing Enforcement Social Behaviours, enforcement H = Rating, Reliability, Robustness Recycling, Cost analysis Design Analysis Prototyping

Field Testing (road, terrain, tyre, environment, infrastructure), measurements F= Energy consumption (V) Lightweight Physical and Virtual

3 Our Mission Supporting automotive industry with innovative and research intensive solutions Vehicle Lightweight/Energy Crashworthiness Integrated Safety Seat / Comfort Vibroacoustics Human Biomechanics Environment Infrastructure Cost-benefit Mechatronics

Crashworthiness Integrated Safety Seat / Comfort Vibroacoustics

4 CAT Offering Technologies Multiphysics Vibro-acoustics Materials Biomechanics Lightweight Reliability Testing Simulation VT Integrated Safety Shape Optimisation Composites ALE Motorsport Automotive Segments Tyres Off-Road Vehicles FSI Mechatronics Robust Optimisation Coaches Roll-over Seats / Restraint systems Comfort

Optimisation Composites ALE Motorsport Automotive Segments Tyres Off-Road

5 Lightweighting mass reduction Low CO 2 Low Fuel Consumption Design optimisation for weight, cost, performance Experimental Modelling & Simulations Optimisation tools such as Lightweight Structures Multi-material design FEM simulations Structural Dynamics

Simulations Optimisation tools such as modefrontier @ Lightweight

6 Component Lightweighting Thermoplastic Engine Oil Pans Future vehicle engines will have plastic oil pans (components) Lightweight Cost efficient Greener i.e. Fuel, Noise, Vibration

7 Flying projectiles & road debris Material Data mining Components e.g. tanks Windscreen Glassware FEM simulations

8 Nanocomposites

9 Nanoparticles improve cell structure Perpendicular Parallel Parallel II (to the direction of foam s growth)

10 Nanoreinforced materials Load vs time graph obtained from drop tower impact test

11 Motorsport Design Specifications: Electrical and/or Mechanical system Lap simulation modelling Competitive advantage of the system Cost of development of a prototype Cost of production units Technology support required when used by teams Flywheel Technology

system Cost of development of a prototype Cost of production

12 Cranfield Impact Centre Owned by the School of Applied Sciences 1.3m crash facility A world renowned leader in the field of safety and safety structures. Recognised centre of excellence for crash and safety testing and simulation (homologation, EUresearch, collaborations with software companies)

13 CIC - safety Analysis, design, development and testing of safety structures Vehicle and occupant simulation Design for crashworthiness and crash protection Pedestrian and cyclist impact modelling

14 CIC Test Rigs Moment of Inertia Roll Over Large Pendulum High Speed Pendulum New Sled HGV Cab Pendulum Rollover Platform; Full scale Seat Test Lab; VCA Approved Hoop Test/Crush Rig; FIA Approved Panel Intrusion / Crush Rig; FIA Approved

Platform; Full scale Seat Test Lab; VCA Approved Hoop

15 Simulation and Virtual Testing CAD/CAE IDEAS (SDRC), Hyperworks, FEA LS DYNA-3D, RADIOSS, PAMCRASH, MADYMO, NASTRAN, ANSYS, AMESIM CIC-SIM In house devised program family for the development of crashworthy 3-D framework type structures Optimisation and robustness GENESIS, ModeFrontier In house Codes Thermal, SEA, FEA, Stochastic, Material Identification, data mining

development of crashworthy 3-D framework type structures Optimisation and robustness

16 Biomechanics Injury thresholds Active muscle Hybrid models

17 Cranfield/JLR Centre for Simulation Technologies Mission: Supporting JLR with cost-effective, innovative and research intensive solutions for simulation based technologies The objectives of the Cranfield/JLR CoE for Simulation Technologies are: To enhance industrial performance in Computational Methods (CAE, ALE, NVH, Optimisation and Robustness) and simulation technologies Application Implementation Development To provide advanced tools (SW/HW) and competitive research outputs Structural integrity and light weighting Human vehicle interaction Reliability and risk analysis Energy and environmental Virtual prototyping and testing Simulation Developments Applications Implementations

Robustness) and simulation technologies Application Implementation Development To provide advanced tools (SW/HW) and competitive research outputs Structural integrity and

18 Simulations in Mechanics Implementation Integrated Safety System simulation Driving Simulation Applications Process Automation Material Modelling and characterisation Research Fellowships PhD Biomechanics Developments Cost-benefit Risk Analysis PhD/Mres MSc Reliability and Robust design Structural Design Cranfield/JLR CoE for Simulation Technologies Short Courses Workshops Teaching

PhD Biomechanics Developments Cost-benefit Risk Analysis PhD/Mres MSc Reliability and Robust

19 Vehicle Metrics Tyre and Soft Soil Modelling Validate and develop mathematical models Establish Base data for force systems, different tyres in sand, sandy loam and clay Tyre forces Vehicle assessment Vehicle design/ development/optimisation. Mobility performance prediction

tyres in sand, sandy loam and clay Tyre forces Vehicle assessment

20 Controlled testing environment

21 Group Summary SAS Sustainable Systems Water Ress./Waste Energy Risk Centre for Automotive Technology Mechatronics Vibroacoustics Biomechancis Impact Centre Motorsport Off-road Dynamics Comfort Crash Safety Teaching Teaching Injury Materials Impact Interactions Sensing CAE Modeling Data Acquisition Aero Road Nano VT Composites SUV Agr. Defense Aero. Space

Simulation Data and Process Management: Why PLM Integration is Critical?

Simulation Data and Process Management: Why PLM Integration is Critical? NAFEMS September 27, 2007 Eric Riedy Teamcenter Proven Leadership Companies trust UGS to manage product knowledge 3,000,000 licenses