Torsion damper design A snapshot of Vibromech s design and development services Vibromech Engineers & Services Ltd. 115, Industrial Estate, Perungudi, Chennai, Tamil Nadu, India, 600 096
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
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
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
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
Customer inputs Customer inputs 11 page questionnaire Functional requirements Mounting details Simulation inputs Customer specific requirements Life Warranty System requirements and guidelines
Customer inputs engine data questionnaire
Vibration simulation Determine no damper vibration levels Determine type of vibration Rigid body Torsional Mode shapes and frequencies
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 1410 2 350 Hz Damper 350 9527.13 333 520 3 360 Hz Damper 360 10079.31 341 522 4 370 Hz Damper 370 10647.05 348 524 5 380 Hz Damper 380 11230.35 355 527 6 390 Hz Damper 390 11829.19 362 530 AVL Excite Designer VESL developed software FEA software
Vibration simulation Determine acceptable vibration levels Determine crankshaft stresses 3D model of crankshaft Material properties Flywheel optimization FEAD inputs
Product design Concept selection and proposal Selection of type of damper Functional simulation and parameter finalization Detailed design
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
Concept proposal and selection Considerations Performance Strength Ease of manufacture / process complexity Detail design Examples in next slides
Concept selection example Concept 1 Concept 2 Concept 3
Concept selection example Factor of safety Concept_1 : 2.01 Concept_2 : 2.54 Concept_3 : 3.16 Von misses stress
Concept selection example
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
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
Detailed design Strength Mounting analysis Crank nose torque Power dissipated Packaging FEAD provisions Other accessories
Detailed design
Detailed stress analysis
CAE Capability CAD facilities in place Interfaces to customer CAD requirements possible ProE in use, converters available Finite element analysis Product analysis Design optimization
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
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
Product test lab
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
Product Testing Customer Engine testing Performed at the customer by us Test equipment available with us Engine endurance Tear down analysis Tested sample analysis
Other Design Methods Used Quality function deployment (QFD) Design for assembly (DFA) Product benchmarking Extensive DFMEA New technology deployment reviews
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
Questions Commercial Technical mahesh@vibromech.com Phone marketing@vibromech.com +91(44) 52005330 Fax +91(44) 52005340