AUTOMOTIVE PLASTICS CAE   Dr. Jay M. Mahishi

 

There are a number of analysis tools available to perform FEA of plastic components. But to perform CAE of these components requires understanding of the plastic materials and the applications. Plastics offer an innovative way of reducing weight and cost by parts consolidation, ease of manufacturing over metals but they pose several engineering challenges.

 

The first secession will discuss the CAE challenges and analysis approaches

 

SESSION 1 GENERAL ENGINEERING CHALLENGES                                                                   8am-12.00 noon

    

*      STIFFNESS AT EXTREME TEMPERATURE

          It is important to identify whether the part is stiffness or strength critical. Some components require          that the deflection does not exceed a certain limit from functionality or from vibrational point of view.

          Most plastics considerably loose their material stiffness at higher temperature.

*      STRENGTH AT EXTREME TEMPERATURE

          The maximum stress is critical in many components that are supporting direct loads.

 

 

                                                Break                                                           9-50am-10-10am

 

 

*      THERMAL / MOISTURE STABILITY

          A number of plastic components that meet the strength and stiffness requirements fail in buckling that           is often not validated

*      DURABILITY

          Failure of plastics is different from metals and requires different approach

*      ENERGY ABSORPTION/CRASHWORTHINESS

          Plastics provide excellent energy absorbing counter measures for occupant safety during crash

 

 

SESSION 2 ANALYSIS APPROACHES FOR DURABILITY                                                               1.00pm-5.00pm

 

*      LINEAR/NON-LINEAR STATIC

          Almost all plastics have a non-linear stress strain curves, but a linear analysis may be performed for initial         sizing

*      LINEAR/NON-LINEAR THERMAL

          It is critical to validate at extreme temperature using appropriate material stress strain curves. In case of     constrained parts the strains due to thermal expansion should be included. In some of the HVAC application the           temperature gradient also becomes critical

*      VISCO-ELASTC/PLASTIC- CREEP

          Plastics are viscoplastic and require appropriate validation

 

         

                                      Break                                                                               2.50pm-3-10pm

 

          CASE STUDIES

 

*      SERVO MOTOR BRACKET Under the hood component that is subjected to static, dynamic, thermal loading

*      SIDE MIRROR HOUSING

*      SEAT COVERS

*      CONSOLE

 

 

 

 

 

 

 

 

 

 

 

SESSION 3 ANALYSIS APPROACHES FOR NVH                                                                         8am-12.00 noon                                                                      

 

*      DYNAMIC NATURAL

          Special attention is required in deciding stiffeners and bosses and attachment points

*      DYNAMIC FORCED

          The interior plastics significantly contribute to the interior acoustics

*      SQUEAK AND RATTLE

          Requires evaluation of Modal interferences

 

                                                Break                                                           9-50am-10-10am

 

 CASE STUDIES

          

*      INSTRUMENT PANEL

*      SIDE MIRROR HOUSING

*      BACK PANEL

 

 

SESSION 4 ANALYSIS APPROACHES FOR CRASH                                                                      1.00pm-5.00pm

 

 

 

*      CRASH AND OCCUPANT SAFETY

      (FRONT, SIDE, REAR, HEAD IMPACT, PEDESTRIAN IMPACT)

          Occupant injuries index can be significantly reduced by CAE of the Interior Plastic components that     come in contact with the occupant during crash

*      OPTIMIZATION

 

 

                                      Break                                                                              2.50pm-3-10pm

 

 

CRASH CASE STUDIES

          

*      KNEE BOLSTER FRONT IMPACT

*      DOOR TRIM SIDE IMPACT

*      A-PILLER, ROOF HEADLINER FOR HEAD IMPACT

 

OPTIMIZATION CASE STUDIES

*      HEAD LINER COUNTER MEASURE