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Architecture Group Activity Report October 14, 1999 November 10, 1999

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... and tools for weight reduction on Ford light-to-medium pickup trucks. ... Explorer XLT/1999 Jeep Grand Cherokee and 1998 Ford Explorer/1998 Dodge Durango) ... – PowerPoint PPT presentation

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Title: Architecture Group Activity Report October 14, 1999 November 10, 1999


1
Architecture 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
2
Architecture 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
3
Architecture 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.
4
Vision 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.

5
Product 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.
6
Architecture Group Phase I Tasks
  • Perform a comprehensive architecture technology
    review
  • Perform architecture benchmark studies
  • Develop architecture assessment methodologies
    compatible with Ford design practices

7
Architecture 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

8
Architecture 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

9
Architecture 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

10
Relationship Among Architecture Groups Primary
Phase I Tasks
11
Work 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.

12
Work 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

13
Work 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

14
Work 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

15
Architecture Group Phase I Tasks, Schedule,
Responsibilities, and Progress
16
Problems 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

17
Architecture Assessment Methodology
18
Example Architecture Concept
Components for an integrated bed/box/frame
structure
19
CAE 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)

20
CAE 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

21
Grey-Scale Rendering, Ford ANSYS Model of P225
Crew Cab
22
CAE 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

23
Technical 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

24
Administrative 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
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