Systems Partner for Chassis. concepts development testing protoparts vehicle conversion projectmanagement

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Anne Flowers
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1 Systems Partner for Chassis concepts development testing protoparts vehicle conversion projectmanagement

2 Sites of IAMT Group, Turnover and Employees Design Simulation Testing Test rigs 150 Employees Weischlitz Magdeburg Berlin Munich Stuttgart WOB; ING Design Simulation 35 Employees Bochum Dresden Bochum Wolfsburg Berlin Magdeburg Wroclaw Dresden Weischlitz Stuttgart Ingolstadt München Simulation 15 Employees Wroclaw

3 Design Pro/Engineer CATIA (V.4 and V.5) Pro/Mechanica, CATIA-FEM Unigraphics Simulation MSC-Patran, HyperMesh MSC-Nastran, Optistruct Abaqus Ansys FEMFAT, ncode ADAMS/Car, VL Motion Equipment and Capacities CAD / CAE Projekt Engineering Munich, Stuttgart, Wolfsburg, Ingolstadt, Weischlitz Office Area: 1.000m 2 Hall Area: 3.200m 2 SeparatedTestingRooms NC-Tooling

4 System Competence Chassis Layout Virtual Loads Package Virtual Design Kinematic Technology Optimization Prototypes Detailed Design Virtual Design

Range of Services Automotive industry Commercial vehicle industry Development of axle components and systems for volume cars and vehicle derivates Package analysis elasto-kinematics (multi-body

5 Range of Services Automotive industry Commercial vehicle industry Development of axle components and systems for volume cars and vehicle derivates Package analysis elasto-kinematics (multi-body system simulation) Technology benchmarks Structural parts: design draft technology-oriented Structural parts: optimization, unmachined and finished-part construction Calculation of strength and fatigue (FEM, damage calculation) Interface design (bearings, bushings, screwed connections, joints) Development-accompanying tests Quality tests (function, strength, fatigue) Prototypes Project integration / series production support up to SOP Interfaces and supplier management Systems partner from design draft up to release and SOP

6 Key Areas and Experiences Structuralparts -chassis: 20 years of experience in development Specialistknowledge of chassispartsand sub-assembliesof steel and aluminium Light-weightdesign Numericalmethods: Design / topologyoptimization Complex structureanalysis and optimization, non-linear FEA Engineering strength(damage calculation) Experimental methods: Multi-channelfatiguetests Test derivations Experimental damage analyses Interfaces: Ball-joints(research, test) Interfaces (design of part interfaces, bearings, screwed connections) More than 20 years of chassis competence Assemblies designed to meet function, strength, service life and techn. requirements

7 Topology Optimization / Lightweigt Design Methodical Competences Thread Joints Weld Seams

8 Methodical Competences Fatigue Simulation

9 Technological Competences Forging Casting Sheet metal / Welding

10 References: Chassis Systems Chassis Audi R8 quattro RUCA (forged) RLCA (forged) Rear Tie Rod (profile) Wheel carrier (casted) Brackets (weldes) Screwings FLCA (forged) FUCA (forged) knuckle (CPC) Conecting Rod stearing gear (welded) Brackets (welded) Screwings

11 System Competence Chassis Protoparts Mule cars Testing Testing Measurm. Test Determ. Load data Load determination and Testing

refrigeratingsets Special testbenches(vehicle

measuringsystem for field measurements Special

12 Equipment and Capacities Testing Servohydraulic testingapparatusmts (45 actuators, 25 kn kn, FlexTest II, RPC pro) 3 Environmental chambers(-40 C C, 3K/min, humiditysimulation), refrigeratingsets Special testbenches(vehicle joints, steerings, whee hubs) Mobile measuringsystem for field measurements Special measuringand evaluation software for road load data determination Straingage measuringinstruments, measuringamplifiers Axle Test Stand (8 actuators)

13 Test Lab

14 Whole axle test rig Axle Test Rig (13 actuators)

15 Testings: Strength, Fatigue, Waer Testing of Subframes & Stabilizer Systems Testing of Wheel controlling parts Testing of chassis components

16 Testings: Strength, Fatigue, Waer Steering Systems Waer testing of ball joints (AK-LH14) Leakage testings of ball joints (AK-LH14) Wheel Hubs / Wheel Bearings Testing of steering components

17 Methodical Competences MBS Simulation Internal Loads Dynamics

18 Special Competences Derivates Suspension development / Qualifying for derivates, niche vehicles and premium cars Takingover of conceptsand adaptionof chassisfor new vehicle loads Calculationof internal loads / elasto kinematics(mbs-simulation) and definition of requiremets(componentspecifications) Responsibleccordinationand development of the completesuspension including all structural parts up to SOP Coordinating of and voting with all internal and external partners Calculationstrengthand fatigue (FEA s, Damage Calculation), Release Documentation Layout for interfaces(bearings, thread joints, bushings) Tests (function, strength, fatigue) Leading, pushing and controlof completetests, releasesand variations (resident team)

19 Development of complete suspension system for BMW Safety Car Special Competences Derivates -Layout for structural parts and interfaces -Linear and non-nonlinear structural analysis (parts and interfaces) -Geometrical Integration (Package, Concept, Tolerances, ) -Integration of vehicle dynamics -Vehicle Integration (modular platform) -Supplier control, scheduling - Co-ordination, preparing und caring of Prototype assembling -Co-ordination and voting with Plants and Logistics -Preparing and Planning of Releases and Sourcing -Integration Operational Strength -Caring, Co-ordination and implementation of component tests -Caring and Co-ordination of system and vehicle tests -Management of changes -Reporting -Preparing and adaption of specifictions with suppliers -Preparing and caring of system and process FMEA s -Preparing and caring of serial production process at the suppliers

20 Steering Integration steering gear and pipes (routing, conectors) Responsible coordination Voting with proto deptm. Testings References Chassis systems Suspension / Damper/ Stabiliser Conception of interfaces (thread joints, supporter ) Conception of stabiliser (routing, package, diamater...) Layout of stabiliser and optimization (tube, brackets, bearings etc.) Responible coordination with suppliers Design and testing of suspension brackets Testing of dampers Break Systems Coordination of suppliers (break body, break disk) Design (protection plate, tube) Layout and validation of thread joints

Vehicle Reconstruction and Measurements Manufacturing of modified parts Manufacturing of modified parts using Prototype technologies Measuring of the parts and documentation Development

Components Mounting and connecting of peripherical units Application of Measuring Equipment Measuring of axles Implementation and Evaluation of Measurings Measurings of forces,

21 Vehicle Reconstruction and Measurements Manufacturing of modified parts Manufacturing of modified parts using Prototype technologies Measuring of the parts and documentation Development an Construction Mounting concepts for Measuring Equipment Package Construction of Measuring Components and integration Vehicle Reconstruction Disassembly and Mounting of Measuring Components Mounting and connecting of peripherical units Application of Measuring Equipment Measuring of axles Implementation and Evaluation of Measurings Measurings of forces, accelerations, displacements Evaluation and documentation Project Management Projekt Monitoring (Scheduling, Costs, Project Progress) Preparation of releases Interface Management (OEM Supplier IAMT)

22 Equipment and Capacities: Prototypes Design Simulation Tests Test Rigs Prototype Reconstructions Assembling of Measuring Cars

..) Sourcing of parts (fully machined parts, welded parts, sand casted parts,.

23 Prototypes Prototype Parts Typical Services Management of Interfaces and Suppliers (Votings, Scheduling,...) Sourcing of parts (fully machined parts, welded parts, sand casted parts,...) Management for purchased parts Assembling (eg. brackets, mounting of bushings,...) Delivery of completed prototype parts

24 Benefit of a Partnership with IAMT Deep specialised Systems Partner for chassis develpoment with own process know how System Partner for Construction, Simulation, Tests and Prototypes Responsible Project Management during the complete project Competent and effective Support for Customers Chassis Design Dept. Production Process Competence and supplier network for Aluminium + Steel components Reduced Interfaces, only 1 resp. development partner for Industrialisation of concepts Central interface function for supplier network in Germany / France / Italy,. Experiences in management of complexdevelopment projects Saves reccorurces of Customer Responsible Controlling of development processes at Suppliers Future Cooperation with IAMT

$ISO\IEC 17025:2005 QMS Extension for Aerospace$

25 QMS-Zertification according DIN EN ISO 9001:2005 Accreditation as independent Test Laboratory DIN EN ISO\IEC 17025:2005 QMS Extension for Aerospace Industry according DIN EN 9100 Unternehmenspräsentation IAMT Engineering

WEIGHT OPTIMIZATION OF STEERING KNUCKLE FOR FOUR WHEELERS ****

WEIGHT OPTIMIZATION OF STEERING KNUCKLE FOR FOUR WHEELERS, 1M.Tech (Machine Design), B.L.D.E.A s V. P. Dr.P.G.H College of Engineering and Technology, Vijayapur, Karnataka, India 2Professor, Dept. of Mechanical