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Design, Validation, and Optimization of a Rear Sub-Frame with Electric Powertrain Integration THESIS Presented in Partial Fulfil

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Design, Validation, and Optimization of a Rear Sub-Frame with Electric Powertrain Integration THESIS Presented in Partial Fulfil Design, Validation, and Optimization of a Rear Sub-frame with Electric Powertrain Integration THESIS Presented in Partial Fulfillment of the Requirements for the Degree Master of Science in the Graduate School of The Ohio State University By David Michael Walters, B.S. Graduate Program in Mechanical Engineering The Ohio State University 2015 Thesis Committee: Dr. Giorgio Rizzoni, Advisor Dr. Shawn Midlam-Mohler Copyright by David Michael Walters 2015 ABSTRACT Government regulations and consumer desire continue to aggressively push automotive manufacturers to improve the fuel economy and emissions of new vehicle designs. Vehicle weight reduction and the use of hybrid electric powertrains are becoming more commonly used methods for addressing a need for improved fuel economy and reduced vehicle emission. EcoCAR 2 is a three year collegiate design competition that involves 15 teams from universities across North America, competing to develop a vehicle with improved fuel economy and reduced emissions. Each team starts with a 2013 Chevrolet Malibu and replaces the powertrain with the primary objective being the reduction of fuel consumption and emissions. The team from The Ohio State University incorporated a rear electric powertrain featuring an electric machine and single-speed transmission into their vehicle architecture. This resulted in the need for a customized rear cradle to support the addition of a rear electric powertrain. An initial custom cradle design was created by modifying an existing steel rear sub-frame to accommodate the addition of the rear electric powertrain. However, in order to reduce total vehicle weight and thus improve fuel economy and reduce emissions, a reduced mass, aluminum rear cradle was created for Ohio State's final vehicle design. This study covers the methodology surrounding the design, validation, and optimization of that final rear cradle design. ii DEDICATION To my loving wife, Laura, who helps me to be the best version of myself; to my parents, Dick and Michele, who have supported me and shaped me into the man I am today, and to my savior Jesus Christ who gives my life meaning. iii ACKNOWLEDGEMENTS I would like to thank Dr. Rizzoni and Dr. Shawn Midlam-Mohler for their guidance and patience through this and other EcoCAR related endeavors during my time at The Ohio State University. Their support and encouragement has helped me in addition to countless other students at OSU's Center for Automotive Research. I would like to thank Josh Hendricks for conducting much of the work surrounding the design and fabrication of the OE modified cradle design as part of this project. I would like to thank all contributors to the OSU EcoCAR 2 team for the camaraderie, support, and commitment to excellence in all things automotive. Lastly, I would like to thank my friends and family for their patience and support during this stressful period of my life. iv VITA June 2005 ..........................................................Circleville High School May 2010 ..........................................................B.S. Mechanical Engineering, Ohio Northern University January 2011 to Present ...................................Graduate Research Associate, Department of Mechanical Engineering, The Ohio State University FIELDS OF STUDY Major Field: Mechanical Engineering v TABLE OF CONTENTS ABSTRACT ...................................................................................................................... II DEDICATION................................................................................................................. III ACKNOWLEDGEMENTS ........................................................................................... IV VITA...................................................................................................................................V TABLE OF CONTENTS ............................................................................................... VI LIST OF TABLES .......................................................................................................... XI LIST OF FIGURES ..................................................................................................... XIII CHAPTER 1: INTRODUCTION .................................................................................... 1 1.1 Introduction ................................................................................................................. 1 1.2 EcoCAR 2 Competition .............................................................................................. 2 1.3 EcoCAR 2 Architecture .............................................................................................. 5 vi 1.4 Motivation .................................................................................................................... 7 CHAPTER 2: LITERATURE REVIEW AND BACKGROUND.............................. 11 2.1 Introduction ............................................................................................................... 11 2.2 Design Considerations .............................................................................................. 12 2.2.1 Material Selection ................................................................................................ 12 2.2.2 System Interactions and Design Constraints........................................................ 14 2.2.3 Environmental Exposure ...................................................................................... 16 2.2.4 Manufacturability ................................................................................................. 17 2.2.5 Crashworthiness and Structural Stiffness ............................................................ 20 CHAPTER 3: TOOLS AND RESOURCES ................................................................. 23 3.1 Design Modeling ........................................................................................................ 23 3.2 Finite Element Analysis ............................................................................................ 24 3.2.1 FEA Process Introduction .................................................................................... 24 3.2.2 Pre-Analysis Processing....................................................................................... 25 3.2.3 Mesh Generation .................................................................................................. 54 3.2.4 Simulation Constraints and Loading Application ................................................ 63 3.2.5 Solving Simulation............................................................................................... 69 3.2.6 Post-Processing Results ....................................................................................... 71 3.3 Manufacturing Technologies ................................................................................... 81 vii CHAPTER 4: SIMULATION LOADING SCENARIOS ........................................... 83 4.1 Loading Conditions ................................................................................................... 83 4.2 Two-Wheel Bump ..................................................................................................... 85 4.3 One-Wheel Bump ...................................................................................................... 85 4.4 Twist: Jounce and Rebound ..................................................................................... 87 4.5 Forward Braking ...................................................................................................... 88 4.6 Reverse Braking ........................................................................................................ 89 4.7 Cornering ................................................................................................................... 90 4.8 Forward Acceleration ............................................................................................... 91 4.9 Reverse Acceleration ................................................................................................ 92 4.10 Max Torque ............................................................................................................. 93 4.11 Reverse Bump.......................................................................................................... 95 4.12 Forward Impact ...................................................................................................... 95 CHAPTER 5: OE MODIFIED CRADLE DESIGN .................................................... 97 5.1 OE Modified Rear Sub-frame.................................................................................. 97 viii 5.2 Component Integration ............................................................................................ 98 5.3 Material Removal.................................................................................................... 100 5.4 Reinforcing .............................................................................................................. 101 5.5 Simulations .............................................................................................................. 103 5.6 Result Processing .................................................................................................... 103 CHAPTER 6: REDUCED MASS ALUMINUM CRADLE...................................... 106 6.1 Approach ................................................................................................................
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