Title: Architecture Group Activity Report October 14, 1999 November 10, 1999
1Architecture Group Activity ReportOctober 14,
1999 November 10, 1999
University of Louisville IMPACT Architecture
TeamGlen Prater, Jr., Associate ProfessorEllen
G. Brehob, Assistant ProfessorMichael L. Day,
ProfessorJ.B. Speed Scientific
SchoolUniversity of LouisvilleLouisville, KY
40292November 11, 1999
2Architecture Group Members
University of Louisville Ellen Brehob Mech.
Eng. 502-852-7825 brehob_at_louisville.edu Mike
Day Mech. Eng. 502-852-6332 mday_at_louisville.edu
Glen Prater Mech. Eng. 502-852-6331 gprater_at_loui
sville.edu Ford Motor Company Musa
Azzouz Ford 313-248-4522 amzzouz_at_ford.com Milind
Baviskar Ford-AVSE 313-322-1181 mbaviska_at_ford.com
Mike Cummins Ford/Argus 703-683-0955 impactext_at_
home.com Pete Duschl Ford-AVSE 313-248-3051 pdus
chl_at_ford.com Steel Industry Ravir
Bhatnagar Ispat Inland 248-358-9243 rsbhat_at_inland.
com Paul Schurter Dofasco Steel 1-800-816-6333 p
aul_schurter_at_dofasco.ca Jody Shaw US
Steel 248-267-2608 jrshaw_at_uss.com Dennis
Urban Ispat Inland 219-399-4337 dmurba_at_inland.com
Blake Zuidema National Steel 734-591-5635 bzuide
ma_at_nationalsteel.com
3Architecture Group Mission
To develop, demonstrate and validate
architectural methodologies and tools for weight
reduction on Ford light-to-medium pickup trucks.
These methodologies will be compatible with
existing Ford design practices and CAE tools.
After validation, the methodologies will be used
for a series of parametric studies involving an
existing vehicle.
4Vision for Success
- Deliver documented, validated methodologies and
software tools that can be used to model and
optimize the design architecture of light truck
platforms, particularly with regard to weight. - Supply to Ford and AISI the results of a
preliminary set of parametric architecture
studies that identify and justify weight saving
opportunities.
5Product Architecture
A machine, or product, is a combination of
physical components that perform functions -
particularly the use, transformation, or
transmission of energy, force, or motion - for a
specific purpose. The architecture of a product
is the way in which functional elements are
implemented in the form of physical components,
and the way the groups interact.
6Architecture Group Phase I Tasks
- Perform a comprehensive architecture technology
review - Perform architecture benchmark studies
- Develop architecture assessment methodologies
compatible with Ford design practices
7Architecture Technology Review
- Perform comprehensive search of the open
technical literature - Review Ford benchmarking methodologies, metrics
and results - Survey applicable Ford design practices and CAE
software tools - Establish required structural performance
attributes (stiffness, modal parameters, etc.) - Collect architecture information on AISI design
initiatives - ULSAB, ULSAC, LTS - Review Army COMBATT requirements and HMMWV
mission profiles
8Architecture Benchmark Studies
- Compile information on existing Ford
architectures, F-150/250 carryover constraints - Collect information on external competitors'
full-size light truck designs - Compare Ford full-size pickups with performance
requirements and benchmark architectures - Identify opportunities for cost savings, weight
reduction, and performance enhancement - Prepare/update running architecture opportunities
list document benchmark studies
9Architecture Assessment Methodologies
- Establish standards for displaying scaled
architecture schematics - Create interpretation standards, formalize
terminology - Select metrics for quantifying modularity, static
stiffness, joint strength, and normalized cost - Perform FEM analyses required to calculate
metrics - Validate methodologies using appropriate case
studies - Perform parametric architecture studies in
support of larger benchmarking effort - Document architecture methodologies and tools
10Relationship Among Architecture Groups Primary
Phase I Tasks
11Work Completed, 10/14-11/10
- Technology Review
- Continued abstracting pertinent papers for
inclusion on web site. - Proceeded with review of sample Ford Benchmarking
Summary Management Review reports (1999 Ford
Explorer XLT/1999 Jeep Grand Cherokee and 1998
Ford Explorer/1998 Dodge Durango). - Reviewed technical reports documenting AISI
ULSAB, ULSAC, and LTS projects. - Surveyed IVV procedures manual from TRW, Inc.,
and Battelle Memorial Institute. Web sites for
several firms offering contract IVV services to
the U.S. Military and private industry.
12Work Completed, 10/14-11/10 (Continued)
- Architecture Benchmark Studies
- Circulated request within group for architecture
concept proposals - Generated concept at UL for integrated
bed/box/frame structure - Completed initial CAE file transfer from Ford
- Collected architecture ideas from team members
13Work Completed, 10/14-11/10 (Continued)
- Architecture Assessment Metrics/Methodologies
- Devised 2-D plans for architecture schematics
representing component size, mass, position, and
interactions - Prepared outline for architecture assessment
methodology that includes classification and
grouping of metrics - Created format for documenting metrics
- Prepared detailed description of strain
energy-based metric using documentation procedure - Developed outlines for metrics assessing joint
properties, geometric integration, and functional
integration
14Work Completed, 10/14-11/10 (Continued)
- Project Administration
- Prepared draft Phase II work plan
- Drafted position ads for Phase I/Phase II
personnel - Met with UL Associate Dean for Research
discussed Phase I/Phase II facility needs
15Architecture Group Phase I Tasks, Schedule,
Responsibilities, and Progress
16Problems Encountered, 10/14-11/10
- Hardware and software difficulties related to the
transfer of CAD/FEM files - Architecture concept formulation is hampered by
lack of real-time access to vehicle hardware and
component drawings - Hardware/software platform
- Uncertainty about participation-level by non-UL
Architecture Team members - Contract/budget is not finalized for either Phase
I or Phase II work
17Architecture Assessment Methodology
18Example Architecture Concept
Components for an integrated bed/box/frame
structure
19CAE File Transfer Issues
- ANSYS Model
- Input file (14MB file) exceeded the limits of the
educational version of ANSYS used at the
University of Louisville - Now in the process of upgrading to the university
research version of ANSYS (limit of 120,000 nodes
and 120,000 elements)
20CAE File Transfer Issues (Continued)
- I-DEAS Model
- Imported I-DEAS simulation universal file (35 MB
file) - 165,000 Nodes, 162,000 (thin-shell) elements
- Detailed model of P225 crew cab
- Long display times on current workstations (5
minutes) - Virtual tear-down in progress
- Concentration on frame geometry in support of
current architecture opportunities and specific
IMPACT Phase II tasks
21Grey-Scale Rendering, Ford ANSYS Model of P225
Crew Cab
22CAE File Transfer Issues (Continued)
- Short Term CAE Needs
- CAD drawings of frame(s)
- Information on current cross-sectional and
material properties - Component solid model files for bed structure and
frame rails
23Technical Work Planned, 11/12-12/8
- Generate architecture schematics for P225 crew
cab systems - Perform FEM analyses in support of integrated bed
architecture concept - Continue formulation of architecture metrics
- Evaluate architecture metrics using integrated
bed concept - Formalize architecture concept documentation
standards and assessment process - Proceed with assessment and prioritization of
group-generated architecture concepts - Initiate dialog with Ford regarding cost models
- Phase II technical tasks
24Administrative Work Planned, 11/12-12/8
- Initiate search for technical staff
- Prepare UL press release for Senator Mitch
McConnell - Respond to local publicity requests for UL
- Finalize Phase II work plan/contract arrangements