The IPM GROUP Farmington Hills, Michigan

1
The IPM GROUPFarmington Hills,
Michigan
2
Contact us

• Beni Dror
• 27003 Hills Tech Drive
• Farmington Hills, MI 48331
• Tel [phone],
• Fax [phone]
• e-mail bdror_at_ipmworld.com
• Web www.ipmworld.com
• Mail Address P.O.Box 252223
• West Bloofield, MI 48325

3
Tactical Wheeled Vehicle Weight Reduction
Initiative

• May, 2004
• By
• International Projects Management (I.P.M) LLC
• Phone [phone]

4
Preamble

• The attached are Examples of an on going weight
  reduction initiative for the HUMVEE.

5
PROGRAM

• Selected Components were analyzed to
  re-engineered to reduction weight by 15-20
• Brackets, Brackets Supports Transmission
  Supports.

6
Potential

• Additional Components Under consideration
• Alternator support bracket
• Chassis beams
• Engine components

7
Material and Manufacturing Method Selection

• Selecting the most appropriate material and
  manufacturing methods according to the part
  loading and stiffness.
• Special welding processes of high strength steel
  sheet
• More Accurate Casting process to reduce tolerances

8
Using FEA methods

• Using Finite Element Analysis enables us to
  refine the stress distribution under more
  realistic load application and attachment
  conditions, eliminating the inherent conservatism
  present in the original calculations.
• Material lightly loaded can then be safely
  trimmed from the original part.

9
Examples of FEA used for weight reduction.

• Part No. 12338191- Spring Seat
• from 10.9 lbs to 9.4 lbs
• Part No. 12469497- Alternator Support
• from 25.3 lbs to 21 lbs
• Part No. 12469498- Compressor Bracket
• from 9.8 lbs to 8.1 lbs

10
Stress Report AbstractPart No. 12338191

• Compiled
• Name J. Hornstein
• Title Stress Engineer
• Checked
• Name J. Hornstein
• Title Stress Engineer
• Approved
• Name Dr Fredy H. Ornath
• Title CEO Materials Systems

11

• 1 Subject Spring Seat, Front, Stress Analysis
• Scope
• The scope of this report is to compare the
  strength of the proposed-design to the current
  design of the subject part under the same
  stipulated set of external loads. Currently the
  part is a low alloy, steel sheet (Ftu 60 ksi)
  welding assembly while the new design is a
  casting made of ductile iron of higher strength
  (Ftu 100 ksi).
• Abstract
• A coarse FEM of the current (welded) part was
  created and subjected to the stipulated set of
  applied loads.
• The internal loads, (reactions at the rail
  attachment and the part displacements and
  stresses) were calculated.
• The geometry of this model was then modified to
  represent the proposed design, retaining the
  loading and reaction system and the internal
  loads were calculated again.
• A strength comparison was then performed
  considering both internal loads and material
  properties and a safety factor for the proposed
  part was calculated when applicable.
• Conclusions and Recommendations
• The maximum calculated stresses in the current
  part are exceeding the UTS of the material in the
  attachment flanges, which is attributable to the
  inherent conservatism of the analysis. On the
  assumption that the part had passed the
  certification tests this should not be a matter
  of concern.
• While the strength of the proposed part is
  exceeding the strength of the current part,
  because of the materials low elongation (3 vs.
  22 for the current design) it is recommended to
  eliminate hot spots of tensile stresses above
  100000 psi by extending the lower bosses all the
  way to the horizontal flanges (see Figure 2.1.1
  on the next page)
• References

12
Current 12338191 image
13
Current 12338191 - welding
14
New 12338191 - casting
15
12338191 Welding FE Model plot
16
12338191 Casting FE Model plot
17
12338191 Welding FE Results plot
18
12338191 Casting FE Stress plot
19
Part No. 12338191

• Stress Report
• Open 12338191_Stress_Report_Abstract.doc

20
12469497(R) and 12469498(L)
21
Stress Report AbstractPart No. 12469498

• Compiled
• Name J. Hornstein
• Title Stress Engineer
• Checked
• Name J. Hornstein
• Title Stress Engineer
• Approved
• Name Dr Fredy H. Ornath
• Title CEO Materials Systems

22
12469498 Original part
New Part Weight reduction accomplished by
opening cutouts in original part
23
12469498 Original - FEM
24
12469498 Redesigned - FEM
25
Part No. 12469498

• Stress Report
• Open 12469498_Stress_Report_Abstract.doc
• NoteAluminium Cast Alloy (e.g. 300 Series
  Aluminium Cast Alloy, MIL-HDBK-5G chapter 3.9)
  could offer acceptable strength, while reducing
  the part weight to a third of the current 9.8 lbs

26
Stress Report AbstractPart No. 12469497

• Compiled
• Name J. Hornstein
• Title Stress Engineer
• Checked
• Name J. Hornstein
• Title Stress Engineer
• Approved
• Name Dr Fredy H. Ornath
• Title CEO Materials Systems

27
12469497 Redesigned part
Weight reduction accomplished by opening cutouts
in original part
28
12469497 Redesigned - FEM
29
Part No. 12469497

• Stress Report
• Open 12469497_Stress_Report_Abstract.doc
• NoteAluminium Cast Alloy (e.g. 300 Series
  Aluminium Cast Alloy, MIL-HDBK-5G chapter 3.9)
  could offer acceptable strength, while reducing
  the part weight to a third of the current 25.3 lbs