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Simulation Driven Product Development of a Thick Laminated Composite Connecting Rod

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Simulation Driven Product Development of a Thick Laminated Composite Connecting Rod Department of Construction Sciences Solid Mechanics ISRN LUTFD2/TFHF-19/5231-SE(1-35) Simulation driven product development of a thick laminated composite connecting rod Master's Dissertation by Adrian Tosteberg Supervisors: P¨ar-Ola Jansell, Deputy Managing Director - Altair Engineering Nordics Daniel K¨ampe, Technical Manager - Koenigsegg Automotive Jonas Engqvist, Research Engineer - Solid Mechanics, Faculty of Engineering LTH Examiner: H˚akan Hallberg, Associate Professor - Solid Mechanics, Faculty of Engineering LTH Copyright c 2019 by the Division of Solid Mechanics, and Adrian Tosteberg Printed by Media-Tryck AB, Lund, Sweden For information, address: Division of Solid Mechanics, Lund University, Box 118, SE-221 00 Lund, Sweden Webpage: www.solid.lth.se Contents 1 Abstract 1 2 Acronyms 1 3 Acknowledgements 1 4 Introduction 2 4.1 Background . .2 4.2 Objectives . .2 4.3 Company background . .2 4.4 Project description . .2 4.5 Boundaries . .2 5 Methodology 3 5.1 General approach . .3 5.2 Pre-study . .3 5.2.1 Product understanding . .3 5.2.2 Scope . .4 5.2.3 Boundary Conditions . .5 5.2.4 Failure and Material Theory . .5 5.2.5 Optimisation Goals . .7 5.2.6 Creation of Design Workspace . .7 5.2.7 Thermal requirements . .8 5.2.8 Chemical Requirements . .8 5.2.9 Manufacturing Options . .9 5.2.10 Know-How and Involvement . .9 5.3 Load step extraction and validation . .9 5.4 Topology Optimization . 10 5.5 Load path analysis . 10 5.6 Design for manufacturing . 10 5.7 Composite Optimisation . 12 5.7.1 Thick laminated composites optimisation . 12 5.7.2 Phase 1 - Free size optimisation . 14 5.7.3 Phase 2 - Ply based Sizing optimisation . 15 5.7.4 Phase 3 - Stacking optimisation . 16 6 Results & Discussion 16 6.1 Pre-study . 16 6.1.1 Boundary Conditions . 16 6.1.2 Mechanical Optimisation goals . 17 6.2 Multi-Body Simulation . 18 6.3 Flex body MBS . 21 6.4 Topology Optimisation . 21 6.5 Load Path Analysis . 22 6.6 Thick Laminate Modelling . 24 6.7 Composite Optimisation . 26 6.8 Manufacturing . 28 6.8.1 Core and Inserts . 28 6.8.2 Molds . 29 6.9 Benchmarking . 30 7 Conclusion 32 8 Appendix 33 Adrian Tosteberg March 13, 2019 1 Abstract This master thesis explores options for efficient simulation in the product development process of a composite part. It’s method is a result of observation of the development process within two leading companies, both renowned specialists in their respective domains. Koenigsegg Automotive, is probably the most famous and carbon fiber intensive supercar producing company in the world. Altair Engineering is a leading simulation based software and consultant company, leading the way in implementation of machine learning and optimisation in the composite product development process. To learn and illustrate the process, a case study is performed: Concept development and optimisa- tion of a thick laminated carbon fiber connecting rod for small volume production series Koenigsegg engine. 2 Acronyms PCP Peak Cylinder Pressure [bar] UD Unidirectional fiber weave Small-end Part of connecting rod that interfaces with piston pin Big-end Part of connecting rod that interfaces with crankshaft Shank Middle section (often profiled) of connecting rod transferring forces between its two ends Gudgeon pin Connects piston to con- necting rod through its small end MBS Multi Body Simulation DOF Degree Of Freedom Figure 1: Nomenclature [2] 3 Acknowledgements To the following persons, I am deeply grateful for your trust, specialist guidance and interest throughout this project: Pär-Ola Jansell, Daniel Kämpe, Jonas Engqvist, Thomas Johansson, Johannes Nelson, Philip Jepson, Urban Carlsson, Lasse Holst, Markus Härder, Christian von Koenigsegg, Anton Llano, Fredrik Hanson, Joakim Truedsson, Erik Magnemark, Fredrik Nord- gren, Vitor Finotto, Fredrik Wettermark, Magnus Lundgren. Keywords connecting rod, carbon fiber, composite optimisation, thick laminate modelling 1 Adrian Tosteberg March 13, 2019 4 Introduction 4.1 Background In the performance car industry, it is argued that lightweight is the main design objective (Chapman[1]). When it comes to quickly rotating parts in the drivetrain, the effect is emphasized, as the dynamic inertia of reciprocating and spinning mass directly affects acceleration and response, efficiency, NVH (noise, vibrations, harshness), fatigue life, wear and vehicle dynamics. In the case of light- ened connecting rods, the weight saving benefits is multiplied, because the balancing system and crankshaft can be further lightened behind it, submitting engine bearings and cylinder liner to less stress and heating. The shift towards the use of carbon reinforced composites for chassis parts has revolutionized the automotive world since the late 90s, but has for various reasons almost completely stayed out of engines and especially engine internals. 4.2 Objectives This study aims to map a robust design process, effective enough to tackle extreme composite ap- plications. It is intended to guide a simulation engineer working with structural composite projects. Furthermore, it will attempt to provide a starting point for further research and developments of composite engine internals. It will address challenges with the working environment and the design procedure, as well as attempt to find a particular solution. 4.3 Company background Koenigsegg Automotive is a world renowned swedish supercar manufacturing company, known for continuously beating their own and others speed and performance world records since the early 2000nds. It is the product of its creator’s Christian von Koenigsegg vision, who together with his team of specialists and craftsmen, keep driving technical innovation in the propulsion and compos- ite sector. Altair Engineering is a leading product development software based company, driven by the core- value of innovation through simulation. The company is dedicated to bringing tools with specialized superhuman abilities, such as machine learning and optimisation, into the various stages of the product lifecycle. 4.4 Project description This study will explore the technical part of the product development process related with design and simulation of a structural composite part. To illustrate the process, a particular solution to a central but widely considered unexplored area of composite applications, engine internals, will be attempted. To illustrate the procedure, a case study of a relatively complexly loaded composite engine connecting rod concept for Koenigsegg is performed. 4.5 Boundaries While it is obvious that the composite product development cycle encompasses more than solely structural and technical solutions, this paper is written with the simple perspective that these fea- tures are the core of value generation, and are prioritized thereafter. The insight that the physical complexity of almost any product will near on infinite, while the development resources are in themselves finitely bound, makes efficiency a critical factor for success. The thermodynamic definition of “efficiency”, is the ratio of the useful work performed by a process to the total energy input. Similarly, in the product development process, this implies the capacity of producing desired results with little or no waste, in the most direct or productive manner available. Setting boundaries for the simulation process equates to a strategic reduction in optimisation resolution over lower priority physical phenomenon. These potential issues are instead left to present themselves and their respective priority during validation and testing. Experience, and the way of the engineering approach, will set the priority list for a particular project. 2 Adrian Tosteberg March 13, 2019 5 Methodology 5.1 General approach The following method is a result from personal product development experience, Koenigsegg’s quality norms, and Altair engineering’s design cycle perspective. It is believed to be general enough for most composite product development processes. 1. Prestudy: Determination of product requirements and input data for simulation (a) Product understanding: explore primary and secondary functioning principles, physical phenomena at play and failure mechanisms (b) Decide simulation scope (c) Collect/calculate necessary mechanical boundary conditions (d) Creation of design workspace (e) Thermal requirements (f) Chemical requirements (g) Explore available manufacturing options and determine requirements (h) Involve and gather experience from key manufacturing players 2. Optimisation of Shape (a) Topology optimisation (b) Load path analysis (c) Design simplification for manufacturing 3. Composite Optimisation (a) Free size optimisation (b) Size optimisation (c) Stacking optimisation 4. Manufacturing and testing (outside the scope of this thesis) 5.2 Pre-study 5.2.1 Product understanding To achieve a perspective of the size and challenges of the project to come, it is sensible to quickly map out the product’s functioning principles. In this case, the primary mechanism, the reason for which a crankshaft exists, is to translate the reciprocating linear motion of the piston to a rotational torque on the crankshaft, which in turn will propel the vehicle. For an in depth understanding of the secondary phenomenon at play in the product, a good starting point can lie in its failure mechanisms. Scanning for relevant studies is a good starting point, otherwise specialists can be consulted while keeping an eye out for solutions already on the market. It is necessary to explore the differences and complications arising from converting a homogeneous
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