Development of a CAE Modeling Technique for Heavy Duty Cargo Weight using a DFSS Methodology
2022-01-0925
03/29/2022
- Event
- Content
- Cargo box is one of the indispensable structures of a pickup truck which makes it capable of transporting heavy cargo weights. This heavy cargo weight plays an important role in durability performance of the box structure when subjected to road load inputs. Finite element representation for huge cargo weights is always challenging, especially in a linear model under dynamic proving ground road load durability analysis using a superposition approach. Any gap in virtual modeling technique can lead to absurd cargo box modes and hence durability results. With the original computer aided engineering (CAE) approach, durability results could not correlate much with physical testing results. It was crucial to have the right and robust CAE modeling technique to represent the heavy weight to provide the right torsional mode of the cargo box and good durability results. As there were multiple variables owing to heavy cargo weight, Design for Six Sigma (DFSS) methodology was used to develop a robust CAE modeling technique. This project was defined with multiple key control factors considering geometrical and material stiffness properties of cargo along with the multiple ways to connect the cargo ballast with box floor. The manufacturing variability of box panels was considered as a noise factor. L18 Orthogonal Array matrix was chosen to optimize the variables based on factorial effects of signal to noise (S/N) ratio. Finally, the validation was done for the achieved optimum solutions using numerical tests. This paper describes the DFSS project in detail, and emphasizes on how the DFSS approach could be very effective to predict the influential control factors and how the combination of multiple factors could be used to find out the optimum solution. This paper also highlights how the optimized CAE modeling technique improves accuracy of the cargo box modes and durability results. This CAE modeling technique developed using DFSS methodology has been implemented in routine durability evaluation of heavy duty pick up cargo boxes and the results have been well correlated with physical testing. Keywords: Computer Aided Engineering (CAE), Design for Six Sigma (DFSS), Control factors, Noise Factors, Signal to Noise Ratio (S/N), Modal Transient Fatigue
- Citation
- Pankaj, A., Nazir, F., Zhang, W., and Guo, M., "Development of a CAE Modeling Technique for Heavy Duty Cargo Weight using a DFSS Methodology," SAE Technical Paper 2022-01-0925, 2022, .