BIW CAE Analysis

Objective:
Explain the main types of automotive CAE Analysis with sample load cases.
CAE Analysis
• Bracket Analysis, Drag Analysis, CFD Analysis.
• CAE stands for Computer Aided Engineering.
• CAE is the broad usage of computer software to aid in engineering Analysis tasks.
• It includes FEA, CFD, and MBD & Optimization.
1. FEA:
• Is a numerical technique for finding approx. solution of partial differential eqn. (PDE) as well as of
integral eqn?
• These PDE are either completely eliminated or broken down into simpler approximations to come to
a solution to the original problem.
• Automotive industry predominantly uses CAE to simulate NVH, Durability & Crash Tests & arrive
at solutions to various problems.
• The Finite Element Analysis (FEA) is the simulation of any given physical phenomenon using the
numerical technique called Finite Element Method (FEM). Engineers use it to reduce the number of
physical prototypes and experiments and optimize components in their design phase to develop
better products, faster.
2. NVH Analysis
• Stands for Noise, Vibration and Harshness. It is related to the discomfort and /or failure that can
be caused to occupants or to the BIW structure due to various sources of Noise and Vibration.
In Automobiles
1. Noise is related to what the passenger can hear due to external sources of vibration.
2. There are various sources of vibration, which can be felt by the passenger such as Engine, BIW, and
Tire Excitation etc.
3. Harshness is the subjective “Feeling”, felt by the occupant which is associated with Noise and
Vibration.
Load Cases for NVH Analysis
A. Global Stiffness
1. Static Bending Stiffness
2. Static Torsion stiffness
B. Normal Modes
Vehicle NVH
• Vehicle Interior Noise and Vibration Refinement
• Noise Source Identification (NSI) / Transfer Path analysis (TPA)
• Noise Transfer Function (NTF), Vibration Transfer Function (VTF) & Acoustic Noise Transfer
function (ANTF) Evaluations
• NVH Benchmarking, Troubleshooting and Test based measurements on vehicles ranging from Two
wheelers, Cars to Commercial vehicles
• Pass-by Noise Source Identification and Reduction
• Sound Quality Evaluation and Improvement
• Pass-by Noise Evaluation as per IS 3028 / ISO 362
• Interior Noise Measurement as per IS 12832 / AIS 020
• Interior Vibration and Harshness Measurement as per AIS 153
• Sub-system / Component level NVH assessment: Intake, Exhaust, Window regulator, Turbocharger,
Door slam, tire, Radiator Fan, Wiper Motor, HVAC, Engine Oil, Transmission Oil, etc.
Tire Noise
• Tire Noise Evaluation using Close Proximity Method (CPX).
• Tire benchmarking - Quantification of Tire Source Strength by Acoustic Transfer Functions.
• Tire Cavity Noise Evaluation and Acoustic Material Characterization to reduce Cavity Resonance.
• Tire TPA to quantify structure-borne and air-borne transfer paths.
• Tire test rig with advanced capabilities to evaluate sound power level, close proximity and cavity
noise evaluations for all passenger car tire applications.
• Intake & Exhaust NVH
• 30+ design Projects with VA/VE using integrated design methodology
• Benchmarking and performance evaluation – Transmission loss, Insertion loss, radiated noise,
dynamic stiffness evaluation etc.
• Simulation for Transmission loss and Back pressure using FEM/CFD tools
 • Design of intake and exhaust for Various applications such as - automotive, tractor, generator and
off road vehicles

Global Stiffness Analysis of BIW Structure

❑ Global stiffness analysis is carried out to check the overall stiffness of the vehicle structure.
❑ From the mechanics of principal we understand that more stiffness means the structure is stiffer and
it can absorb or undergo less deformation.
 ❑ Stiffer the structure more is the tendency of the structure to pass on the vibration to the occupant.
❑ Sources ___Engine, Tire, Steering etc.
❑ More stiffness suggest less vibration absorbing capacity of the structure.
❑ Stiffness is desirable for other attributes in the vehicle, so optimal stiffness is essential for better
performance of vehicle in terms of its NVH characteristics.
❑ Softer the structure better it is image point of view but other attributes requires stiffness.

There are two types of stiffness checks for BIW are

1. Bending Stiffness
2. Torsional Stiffness
1. Static Bending Stiffness
This load case is to test the Global strength
Of the BIW structure on bending mode.
Highlights:-
1. Constrain front and rear shock Towers
2. 1000 N load applied to bending test Rig
3. Check the vertical displacement for calculation of bending stiffness
Structural performance targets: - Static Bending Stiffness =15000 N/mm
If it is less than 15000 N/mm, BIW is a good structure.

Static Torsional Stiffness

1. Rear end are constrained
2. 1000 N of load is applied on Torsion test Rig.
3. Maximum angle of Twist measured to get torsional stiffness value
Structural Performance Targets: - Static Torsional Stiffness = 20000 Newton meter par degree
If it is less than 20,000 Newton meter par degree, BIW is Optimal Structure.
Natural Frequency and Normal Modes:-
Natural Frequency of a system is defined at which a system oscillates on its own free degree of freedom in
the absence of any external forces or any damping.
Normal Modes of BIW
1. Normal Modes is the free motion of an oscillating system at fixed natural frequencies which are
characteristics of the system
2. Natural Frequency and behavior of the structure is checked in normal modes.
3. In CAE, we use different methods to give this initial external Force e.g. Lances method.
4. The strain energies and mode shapes are studied in Normal Modes analysis.
Sr. Body Modes Natural Frequency Mode order
No.

1 Local Roof Bending Mode 40 1

2 Front Lateral Mode 45 2

3 Torsional Mode 52 3

4 Bending Mode 56 4
Four Major Body Modes
Structural performance targets: - Normal Modes (first mode) greater than 40 Hertz
To improve the Global BIW modes, Structural joints can be stiffened.
Crash Analysis
Full vehicle Level
1. Frontal Impact
2. Side Impact
3. Rear Impact
Component Level
1. Seating
2. Roof Crush

Side Impact
❖ Ensure structural integrity (cracking of BIW parts, Spot welds failures etc.)
❖ Measure ‘B’ pillar intrusion into the cabin space also called as occupant zone.
❖ This intrusion should be less than the threshold value.
 Rear Impact
1. Check fuel tank integrity.
2. Check door aperture reductions.
3. Check R point Displacements.
4. Battery interactions in PHEV/ HV.
(Plug in Hybrid electric vehicle / Hybrid Vehicle)
5. BIW plastic strain deformation.
6. Rear casting integrity check.
Frontal Impact
1. Check for dashboard and foot well intrusions
2. Check for toe board intrusion
3. Check for the cowl intrusion
4. Check effective plastic strain for critical components in low speed impacts.
5. Check for vehicle pulse index (VPI)
VPI less than 1, vehicle structure is a good structure
Roof Crush
1. This requirement is designed to protect the occupants in event of a rollover.
2. Roof crush analysis is done to check the strength of the roof structure. The resistance force of BIW is
checked in this load case.
3. Load should be well distributed through ‘A’, ‘B’ and ‘C’ pillar and roof headers.
4. Roof should support load of 3 times of gross vehicle weight, when it is less than or equal to 2722 kg.
5. Roof should support load of 1.5 times of gross vehicle weight, when it is greater than 2722 kg.
6. Roof deformation to be limited to 127 mm into the cabin space.
Durability Analysis
• Related to life of vehicle and it is essentially to confirm the load bearing capability of parts or
structure to meet the deflection criteria.
• In CAE durability analysis is done for design and verification of products using a variety of
structural loads.
• All parts and structures subjected to cyclic mechanical and thermal loading undergo fatigue.
• Fatigue analysis is required to predict component failure under fatigue loading.
Four past Durability Test
1. Front and Rear Recovery Analysis
2. Trailer Towing Analysis

Other Durability CAE Load Cases

1. Luggage Retention Hook Analysis.
2. Floor Pan Fatigue.
3. Roof and Body Side Oil Caning.
4. Vehicle Checking Analysis
5. Vehicle Hoisting Analysis
6. Fatigue Analysis of BIW