Client:
Our client is a major supplier of critical suspension components such as Steering knuckles, Brake drums, Brake discs, Hubs, Brake calipers, Carriers, Differential case to passenger car manufacturers like GM, Ford, Volvo, Honda & BMW.
Scope:
For new Automotive Program, develop an Optimized steering knuckle design meeting the stringent weight target given by OEM and making sure the design meets all the performance targets for:
- Stiffness at attachment locations
- Fatigue life cycle counts for various Service loads
- Permanent set under Extreme Nonlinear static load
- Permanent set under Nonlinear Dynamic loads
- Plastic strain levels under Impact loads
Why APA?
APA Engineering is the CAE technology partner, leading the CAE driven development with 8+ years of experience in CAE drive design development of Steering knuckles and other suspension components, Validating, optimizing ( light-weighting) components, participating and participate in Design review meetings with OEMs, giving a competitive edge to our customers enabling them to win global programs.
Challenges involved:
- Developing a high fidelity model, capturing Bolt Pretension and Shrink fit effects accurately to account for Pre-stress, before applying service/Extreme loads.
- Arriving at a converged solution with nonlinearities such as Material, Geometric and contacts under highly nonlinear loads.
Standards: OEM’s internal standards & Test specifications
Software used:
- Altair’s Hyperworks for Pre & Post Processing
- Dassault System's Abaqus for Solving
Value Delivered:
- Participate in Design review meeting as CAE expert representing our client and proving the lightweight design.
- Entire development cost is just 35 % of the cost of typical consultant charges in USA.
If you would like to know more about this topic.