Design Verification

CAE Methods and Gateway Supports

Objective
1. Explain Design verification
2. Prepare the test methods and apply for design verification
3. Describe a tool at different phases in product development
 What is Design Verification?
Is an essential step in the development of any product (Qualification Testing)?
• Verification Testing can be defined as a method of confirmation by examining and providing evidence
that the design output meets the design input specifications.
• An essential process during any product development that ensures the designed product is same as the
intended use.
• Design input is any physical and performance requirement that is used as the basis for designing purpose.
• Design output is the result of each design phase and at the end of total design effort.
The final design output is a basis for device master record.

What is Design Verification:-

It is useful in project activities like:-
1. Concept through Detailed Design
Detailed design is the phase where the design is refined and plans, specifications and estimates are
created. Detailed design will include outputs such as 2D and 3D models, P & ID's, cost build up estimates,
procurement plans etc.
2. Specification Development
A set of documented requirements to be satisfied by a material, design, product, or service.
3. Detailed Design through to Pre-Production
Vehicles that allow the automaker to find problems before a new model goes on sale to the public. Pre-
production cars come after prototypes, or development which themselves are preceded by concept cars.
4. Production
Are mass-produced identical models, offered for sale to the public, and able to be legally driven on public roads
(street legal)?

Other tools that are useful in conjunction with Design Verification are
1. Requirement Management
2. Configuration Management
3. FMEA
 How to Verify a Design
• Customer hold the testing of products in the same regard as the actual design.
• Customers will assign their own people to witness testing and ensure that it is completed to satisfaction.
• Testing may occur at many points during the design process, from concept development to post-
production.

Conducted with Materials, Models or Subassemblies,

Development test Useful for Determining the Feasibility of Design Ideas,
Gain insights that further direct the Design.

Prototype testing This occurs with items that closely resemble the final product

Proof testing This is another type of design verification testing that employs prototypes

Acceptance testing This is a form of nondestructive testing that occurs with production units
 Design Verification Application and Preparation
Most Common Verification Methods

Demonstration can be conducted in actual or simulated environments

Inspection is usually used to verify related to physical characteristics

Is used in the design of a product and is also used to verify the design and is often
Analysis
the preferred method if testing is not feasible and the cost of testing is prohibited.

this is to check if a design includes features or materials that are similar to those of
Similarity
another product that has made or exceeded current specification

Testing can be one of the most expensive verification methods depending upon
Testing
complexity as well as equipment and facility requirement.
 Preparation of Verification Activities
It involves___________
1. Determining the best approach to conducting the verifications.
2. Defining measurement methods.
3. Identify opportunities to combine verification activities.
4. Identifying necessary tools (e.g. equipment, software etc.) and facilities (e.g. acoustical rooms,
environmental Chambers)
 Conducting Verification Activities
1. Identification and Preparation:
❑ During the development stage of a specification, the identification of verification activity is done parallel.
This enables the designer to make sure that the specification is verifiable. So a test engineer can start
detailed test plan and procedures. Any changes in the specification should be communicated.
❑ Identifying the best approach to conduct verification, define measurement methods, required resources,
tools, and facilities.
❑ The completed verification plan will be reviewed with the design team to identify issues before finalizing
the plan.
2. Planning:
❑ Planning for verification is a concurrent activity with core and development teams. This occurs throughout
the project life cycle. This will be updated as and when any changes are made to design inputs.
❑ During this phase, the software or system under test shall be documented.
❑ Preliminary test plan and test plan refinement are made at this stage. Test plan captures the critical
milestone reducing the project risk.
❑ Tools, test environment, development strategy and identifying the requirements through inspection or
analysis.
3. Developing:
❑ The test case development will coincide with Software Development Life Cycle (SDLC) methodology
implemented by a project team. A variety of test methods are identified during this stage.
❑ The design inputs must be developed including simplest verification activities which are clear-cut and
accurate.
❑ Verification time shall be reduced when similar concepts are conducted in sequence. Even the output of
one test can be used as input for subsequent tests.
❑ Tractability(easily managed or controlled) links are created between test cases and corresponding design
inputs, to ensure that all the requirements are tested and the design output meets the design inputs.
4. Execution of Verification Activities –
❑ A failure to do verification, May invalidate results and may have more direct consequences, if the customer
believes that it was done intentionally, to increase the probability of passing verification or future product
failure lead to legal action.
❑ The test procedures created during the development phase is executed in accordance with the test plan,
strictly following them in verification activity.
❑ If any invalid results occur or if any procedures required modification, it is important to document the
changes and get proper approval.
❑ Any issues are identified and recorded as a defect at this stage.
5. Recording of Results & Reports:-
❑ This activity is performed at the end of each phase of verification execution.
❑ The design verification report gives the detailed summary of verification results which includes the
configuration management, test results for each type of testing and issues found during the verification
activity.
❑ Any non-conformance will be documented and appropriately addressed.
❑ Highlighting Non-Conformance- If a nonconformance (e.g. anomaly (uneven” or “irregular) or failure)
is discovered through verification activities, it is important to first attempt to verify that the
nonconformance is with the product and not due to test equipment or other extenuating factors.
❑ Reviews are done upon the completion of design verification activity and are approved respectively.
❑ The customer may contractually require this records and there may be a prerequisite for obtaining
certifications.
6. Design Validation Process
❑ Some of the designs may be validated by comparing with similar equipment performing similar purpose.
 ❑ When equivalent products are used in the final design validation, the manufacturer must document the
similarity and if any difference from initial production.
❑ Demonstration and/or inspection may be used to validate requirements and other functionality of the
product.
❑ Analyzing the design can be done such as mathematical modeling, a simulation which can recreate the
required functionality.
❑ Tests are performed on the final design that validates the ability of the system to operate as per the
specified design.
❑ Test plan, execution, and results should be documented and maintained as a part of design records. Thus,
Validation is a collection of the results of all validation activities.

Advantages of Design Validation and Verification

❑ We can continuously monitor the designs which enable us to meet the user-defined requirements at every
stage.
❑ Validating the design will point out the difference between how the functionality works and how it is
expected to work.
❑ Documenting the validation procedures will help to easily understand the functionality at any stage in the
future if there might be any change or enhancement made.
❑ Development time will be consistently reduced, improving productivity, which enables to deliver the
product as expected.
❑ Any difference between the outcome and the user need documents must be captured.
❑ It is important to document every activity that occurs during validation, which adequately proves that the
design meets the user requirements.

Gateway Support for Design Verification

The product creation process has different gateways and phases, you need it as shown here------
It is a means to manage the relations between this functions and synchronize theme so different
gateways are______
The product development is series of steps that includes the conceptualization design
development and manufacturing of newly created or newly rebranded foods and services, so the
objective of product development is to cultivate, maintain and increase market share by satisfying
customers.

Part B: - Objective: - Explain CAE Methods for Accessing the BIW

CAE Methods for Design Verification of BIW
Some of the CAE methods which are used for DV of BIW are_____________
1. Structural analysis
2. Fatigue Life Prediction
3. NVH
4. Crash Impact Analysis
5. MBD
6. Thermal Analysis
7. CFD

1. Structural Analysis-
 1. Linear and Nonlinear Static Analysis is used for design verification of products using a
variety of structural loads.
2. Knowing how a design will perform under different static load conditions allows engineers
to recommend changes prior to Physical prototyping.
3. Non-Linearly includes Geometric and Material Non-Linearity Effects.
For example
BIW Recovery, Front Analysis, Rear Analysis, Jacking, Trailer Towing, Winching, Oil Canning,
Luggage Retention, Roof Strength, Self-Weight and Inertia Relief, Static Global Stiffness
Analysis, Strength Calculations, Load Pressure Bearing Limit.
Fatigue Life Prediction
1. All parts and structures subjected to cyclic mechanical and thermal loading will suffer from fatigue. To
predict component failure in such cases requires what's called Fatigue or Durability Analysis.
2. Computer Simulations determine how well parts will hold up during cyclic loading. It can help to predict
how fatigue will affect the overall life of the product and identify the areas that may be critically damaged.
Ex. Spot welds (SPW) failing for minimum Fatigue Life.
 Noise and Vibration
1. Frequency and buckling analysis are critical components of a design and verification process.
2. Inherent vibration modes in structural components or mechanical support systems can shorten an
equipment life and cause unexpected failure.
3. Evaluation of Natural Frequencies or Critical Buckling Loads help in design changes to improve Product
Performance.
Ex. 1) Natural Frequency Analysis
2) Frequency Domain Test
3) Frequency versus Time Domain
4) Random Vibration Test
5) Noise a} Pass by Noise Measurement
B} In Vehicle Noise Measurement
6) Powertrain Noise Measurement
7) Transfer Path Analysis (TPA)
8) Alternative --Model Analysis Approach
 Crash Impact Analysis
• A Crash test is a form of destructive Testing usually performed in order to ensure safe design standards.
• In crash worthiness and crash durability, various modes of transportation or related systems and
components.
• Consumer safety concerns and simulating regulated performance criteria made the OEMs to give
maximum protection to vehicle occupants, under any condition. Behind this effort is advanced virtual
computer simulation using state-of-art software to simulate a variety of global requirements like___
• FMVSS crashworthiness regulations like Frontal, Rear, Side Impact, Roof Crush Resistance
• ECE (Economic Commission for Europe) regulations like deformable 40% offset, Frontal Impact, Rear
Impact, and Dynamic Side Impact.
 MBD-
• Is one that consists of solid bodies or links that are connected to each other by joints that restrict their
relative motion?
• A Study of MBD is the analysis of how mechanical system move under influence of forces also known as
Forward Dynamics.
• The MBD is an expansion of the structural mechanics that provides an advanced set of tools for designing
and optimizing multimode structural mechanics systems using FEA.
• This enables to simulate mixed systems of flexible & rigid bodies, where each body may be subjected to
large rotational or translational displacements.
 • Such analysis helps to identify critical points in MB systems thus enabling to perform more detailed
component level structural analysis.
• The MBD gives the freedom to analyze forces experienced by segments of the structure & stresses
generated in flexible components that may lead to failure due to large deformation or fatigue.
• Transient Freq. Domain, Eigen Freq. & Stationary MBD analysis all performed.
Ex. Four Post Rig Test.

Thermal analysis
• It is done for estimation of Temp. Distribution, Head Flux, Thermal Gradients & Heat Flow,
• Analysis is done for both Steady Flow & Transient Conditions.
Ex. Conduction along & through the Car Body.
 Mold flow analysis
Mold flow, formerly known as C-Mold, is one of the leading software used in process wide
plastics solutions. Mold Flow is developed by Autodesk. It is used for Analysis of Plastic
products. How plastic material flow into mold and what are the effects on that parts are
calculated by Mold Flow.
Following Analysis Perform
1. Fill
2. Flow
3. Cool
4. Warp
5. Runner Balancing
6. Best Gate Location
7. Molding Window
 CFD:
• It is the use of applied math's, physics & computational software to visualize how a gas or liquid flow as
well as how a gas or liquid affects bodies as it flour pass.
• Based on Savior’s Stroke Eqn. describe how the velocity, pressure, temp. & density of the moving fluid
or related.
• Aerodynamics represents a special scientific field that has a huge impact on modern automotive
engineering.
• Aerodynamic deals with the influence of external factors on the observed object, as well as the shape of
the object in order to achieve the desired performance. The aerodynamics forces & coefficients heavily
influence the behavior of vehicles on the road. Drag Force, Lift Force, Lateral Force.
Comparison Between Design Verification and Design Validation
✓ The purpose is to prove with objective evidence that the product satisfies the documents of user needs.
The objective evidence is nothing but any physical proof of the output such as an image, text or audio file
which indicates that the procedure has been accomplished.
✓ Through objective evidence, this process will consistently examine that the product meets the predefined
requirements.
✓ This process involves testing activity, inspection and analysis, and so on.
✓ To provide adequate results, it is required to document the process and follow it systematically.
Verification and Validation With Respect to FEA Flow Chart