AUTOMOTIVE PLASTICS CAE
2 Days Seminar by 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
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
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
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
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
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