Torsion damper design

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1 Torsion damper design A snapshot of Vibromech s design and development services Vibromech Engineers & Services Ltd. 115, Industrial Estate, Perungudi, Chennai, Tamil Nadu, India,

2 Black Box Design & Development Basic inputs from customer Engine data questionnaire CAD data Material properties Concept selection and detailed design Proto development, testing and validation APQP and customer specific systems

3 Damper Design Methodology 1 Customer or database inputs Process Output CAD model and material properties Mass elastic system & Gas pr forces Derive Mass elastic system Vibration simulation (without damper) Mass elastic system Material properties and life requirements Derive strength and vibration limits Acceptable vibration limits, damper requirements & definition, no damper simulation reports Database information Damper proposal development

4 Damper Design Methodology 1 Mounting details, envelope details Customer or database inputs Process Output Vibration simulation (with damper) Customer concurrence to proposal and vibration levels Detailed design Final drawings and specs Drawings, proto control plans etc. Design verification plan Prototype development Prototype bench testing Inspection reports Functional reports

5 Damper Design Methodology 1 Mounting details, envelope details Customer or database inputs Process Output Proto engine test (VESL tests at customer location) Endurance/life tests Damper performance reports, life testing correlation analysis Customer specific requirements Tear down analysis Engineering sign off Kick off & production trial PPAP approval

6 Customer inputs Customer inputs 11 page questionnaire Functional requirements Mounting details Simulation inputs Customer specific requirements Life Warranty System requirements and guidelines

7 Customer inputs engine data questionnaire

8 Vibration simulation Determine no damper vibration levels Determine type of vibration Rigid body Torsional Mode shapes and frequencies

9 Vibration simulation Case No Description Damper Freq Stiffness System Frequency Hz N m/rad Hz 1st Mode 1 No Damper Rigid Inf 526 2nd Mode Equipment/Software used Hz Damper Hz Damper Hz Damper Hz Damper Hz Damper AVL Excite Designer VESL developed software FEA software

10 Vibration simulation Determine acceptable vibration levels Determine crankshaft stresses 3D model of crankshaft Material properties Flywheel optimization FEAD inputs

11 Product design Concept selection and proposal Selection of type of damper Functional simulation and parameter finalization Detailed design

12 Concept selection Crankshaft simulation and analysis for prediction of modes of vibration Vibration amplitudes Crankshaft stresses Joint / mounting analysis Other analysis (Flywheel optimization, bearing design, FEAD) Selection of type of damper to be used for the application Hysteresis (harmonic balancer) Viscous dampers Isolator Dampolator etc

13 Concept proposal and selection Considerations Performance Strength Ease of manufacture / process complexity Detail design Examples in next slides

14 Concept selection example Concept 1 Concept 2 Concept 3

15 Concept selection example Factor of safety Concept_1 : 2.01 Concept_2 : 2.54 Concept_3 : 3.16 Von misses stress

16 Concept selection example

17 Concept selection process complexity Concept I Hub Sheet Metal Tooling (Blanking, Forming, Piercing, Coining etc.,) Pulley Patterns Concept II Concept III Hub Patterns Hub Patterns Pulley Patterns Pulley Sheet Metal Toolings(Blanking,Formin g, Piercing, Coining etc.,) Pulley Roller Fixture Rubber Moulds Rubber Moulds Rubber Moulds Assembly Fixtures & Gauges Assembly Fixtures & Gauges Assembly Fixtures & Gauges

18 Concept selection Pugh concept selection Considers pros and cons Various customer requirements are considered Fact based Considers objective measurable judgments Simple and powerful method Selected concept

19 Detailed design Strength Mounting analysis Crank nose torque Power dissipated Packaging FEAD provisions Other accessories

20 Detailed design

21 Detailed stress analysis

22 CAE Capability CAD facilities in place Interfaces to customer CAD requirements possible ProE in use, converters available Finite element analysis Product analysis Design optimization

23 Prototype development Manufacture Prototype shop Vertical machining centers CNC Skilled operators Experienced supervisors Tool room Pattern manufacture Sheet metal tooling Jigs fixtures Flow forming tooling

24 Prototype development 6 8 weeks for proto development Daily plan and review Production intent tool design Inserts maybe soft (not heat treated) Tool design will be carried over for production with hardened inserts APQP and review

25 Product test lab

26 Product Testing In house Damper Performance tests Strength tests Static load tests Elastomer & Metal Endurance tests Natural frequency Damping Stiffness Elastomer & Metal Engine environment Serial production testing

27 Product Testing Customer Engine testing Performed at the customer by us Test equipment available with us Engine endurance Tear down analysis Tested sample analysis

28 Other Design Methods Used Quality function deployment (QFD) Design for assembly (DFA) Product benchmarking Extensive DFMEA New technology deployment reviews

29 Summary Slide Black box design & development capability CAE capability Other advanced methods in use CAD, FEA QFD, DOE, DFA Quick prototype development 6 8 wks Full range of product and design validation

30 Questions Commercial Technical Phone +91(44) Fax +91(44)

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