Case Study ECOSHELL Bio-Composite Vehicle A full...
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Project coordinator, numerical mock-up, mechanical research, vehicle conception, architecture & dimensioning Case Study Case Study – ECOSHELL Bio ECOSHELL Bio-Composite Vehicle Composite Vehicle A full virtual testing approach with cost reduction solutions A full virtual testing approach with cost reduction solutions Abstract Abstract ECOSHELL, is a Seventh Framework research program (agreement 265838) European project, grouping private companies and research institutes. The target is to design an electrical urban vehicle (category L7e) called “CITI-ZEN”, only composed of bio composite and foam parts, with a weight under 400kg (excluding power and drive train). In this 3-year project, which started in September 2011, CADLM and Cranfield University have jointly realized the materials identification, and are responsible for crash worthiness design of the vehicle. Material samples are provided by Mahytec. Conclusion Conclusion Conclusion Conclusion Company Profile Company Profile CADLM is specialized in modelling and design optimization and is present on many industrial segments (manufacturing, transport, consumer products, biomedical). Our expertise extends beyond FE methods since we exploit fully the complete chain of the know-how leading to a design, using machine learning and data mining techniques. CADLM realises studies and provides software solutions for advanced engineering (system reliability, reduced complexity based robust design), numerical simulation, optimization and on-borad decision support systems based on model reduction techniques. Frontal Crash Simulation Frontal Crash Simulation With the material characterization, CADLM developed a frontal crash model on LS DYNA software based on the ECE-R94 regulations using a frontal deformable barrier (ODB) positioned at 40 % offset. The initial velocity is at 56Km/h. Validation of material characterization in LS DYNA software: Target: identify the material properties for LS DYNA code based virtual model t. Project funded by the European Community under the 7th Framework Programme (2007-2013) Tinitial T final T initial T final T final T initial Example : Composite material Identification (Identical numerical models to Cranfield’s sample test: a velocity is applied at the edges of sample up to failure.) Foam H45 parts ECE-R94 96/79/EG Front ODB European rules Chest compression < 50mm The chest compression value differ according to vehicle equipment and head contact Driver chest compression ~ 27.5 mm Passenger chest compression ~ 18 mm Chest sensor Head sensor ECE-R94 96/79/EG, Front ODB European regulations HIC < 1000 The HIC value differ according to vehicle equipment and head contact Driver HIC=174,1 Passenger HIC=196,9 The bio-composite material targets E = 16090 Mpa G = 4000 MPa Compressive stress at failure 208.4 MPa Tensile stress at failure 144.6 MPa Shear stress at failure 90 Mpa Glue Tensile stress at failure 200MPa Shear stress at failure 200MPa The bio-fidelity dummy criteria are verified. Future work, consist in pedestrian safety aspects as well as human model based evaluation of the injury thresholds. A reliability analysis of the vehicle based on innovative reduced complexity based optimal design developed by CADLM will be published in October 2013. The bio-fidelity dummy criteria are verified. Future work, consist in pedestrian safety aspects as well as human model based evaluation of the injury thresholds. A reliability analysis of the vehicle based on innovative reduced complexity based optimal design developed by CADLM will be published in October 2013. CADLM Parc d’activités du Moulin 43 rue du Saule Trapu 91300 MASSY - France Tel : +33 (0) 1 69 07 29 22 Fax : +33 (0) 1 69 07 28 09 Mail : [email protected] T=0,05s T=0,1s T=0,125s T=0,195s T=0,195s T=0,05s T=0,1s Manufacturing of composite parts, recycling issues Development and testing of natural matrices and binders Regulations standardization Crash test optimization studies, cost-benefit analysis Topology optimization techniques Project management support and dissemination Mechanical characterization, dissemination of project results Characterization of materials, mechanical tests Characterization of natural fibres, testing of composite materials 200kg powertrain + drivetrain Skin Non-woven flax/epoxy composite parts
Transcript of Case Study ECOSHELL Bio-Composite Vehicle A full...
Project coordinator, numerical mock-up, mechanical research, vehicle conception, architecture & dimensioning
Case Study Case Study –– ECOSHELL BioECOSHELL Bio--Composite VehicleComposite Vehicle A full virtual testing approach with cost reduction solutionsA full virtual testing approach with cost reduction solutions
AbstractAbstract European
an composite
University worthiness
ECOSHELL, is a Seventh Framework research program (agreement 265838) European project, grouping private companies and research institutes. The target is to design an electrical urban vehicle (category L7e) called “CITI-ZEN”, only composed of bio composite and foam parts, with a weight under 400kg (excluding power and drive train).
In this 3-year project, which started in September 2011, CADLM and Cranfield University have jointly realized the materials identification, and are responsible for crash worthiness design of the vehicle. Material samples are provided by Mahytec.
ConclusionConclusion
ConclusionConclusion
Company ProfileCompany Profile many
Our the
CADLM (system
optimization
CADLM is specialized in modelling and design optimization and is present on many industrial segments (manufacturing, transport, consumer products, biomedical). Our expertise extends beyond FE methods since we exploit fully the complete chain of the know-how leading to a design, using machine learning and data mining techniques. CADLM realises studies and provides software solutions for advanced engineering (system reliability, reduced complexity based robust design), numerical simulation, optimization and on-borad decision support systems based on model reduction techniques.
Frontal Crash SimulationFrontal Crash Simulation With DYNA software (ODB) positioned
With the material characterization, CADLM developed a frontal crash model on LS DYNA software based on the ECE-R94 regulations using a frontal deformable barrier (ODB) positioned at 40 % offset. The initial velocity is at 56Km/h.
Validation of material characterization in LS DYNA software:
Target: identify the material properties for LS DYNA code based virtual model t.
Project funded by the European Community under the 7th Framework Programme (2007-2013) Tinitial T final
T initial
T final
T final T initial
Example : Composite material Identification (Identical numerical models to Cranfield’s sample test: a velocity is applied at the edges of sample up to failure.)
Foam H45 parts
ECE-R94 96/79/EG Front ODB European rules Chest compression < 50mm The chest compression value differ according to vehicle equipment and head contact
Driver chest compression ~ 27.5 mm
Passenger chest compression ~ 18 mm
Chest sensor
Head sensor
ECE-R94 96/79/EG, Front ODB European regulations HIC < 1000 The HIC value differ according to vehicle equipment and head contact
Driver HIC=174,1 Passenger HIC=196,9
The bio-composite material targets
E = 16090 Mpa G = 4000 MPa
Compressive stress at failure 208.4 MPa
Tensile stress at failure 144.6 MPa
Shear stress at failure 90 Mpa
Glue
Tensile stress at failure 200MPa
Shear stress at failure 200MPa
The bio-fidelity dummy criteria are verified. Future work, consist in pedestrian safety aspects as well as human model based evaluation of the injury thresholds. A reliability analysis of the vehicle based on innovative reduced complexity based optimal design developed by CADLM will be published in October 2013.
The bio-fidelity dummy criteria are verified. Future work, consist in pedestrian safety aspects as well as human model based evaluation of the injury thresholds. A reliability analysis of the vehicle based on innovative reduced complexity based optimal design developed by CADLM will be published in October 2013.
CADLM Parc d’activités du Moulin 43 rue du Saule Trapu 91300 MASSY - France Tel : +33 (0) 1 69 07 29 22 Fax : +33 (0) 1 69 07 28 09 Mail : [email protected]
T=0,05s T=0,1s
T=0,125s T=0,195s
T=0,195s T=0,05s T=0,1s
Manufacturing of composite parts, recycling issues
Development and testing of natural matrices and binders
Regulations standardization
Crash test optimization studies, cost-benefit analysis
Topology optimization techniques
Project management support and dissemination
Mechanical characterization, dissemination of project results
Characterization of materials, mechanical tests
Characterization of natural fibres, testing of composite materials
200kg powertrain + drivetrain Skin Non-woven flax/epoxy composite parts
