Vehicle Safety and Structural Analysis
Ricardo extensively apply Finite Element Analysis (FEA) at all levels of vehicle engineering programmes. Computer models of full vehicles or vehicle components are rapidly constructed from CAD (Computer Aided Design) geometry. Boundary conditions simulating real driving operating conditions can be applied to automatically improve the vehicle structural performance or reduce weight. The time and cost to design and test a vehicle or its components are significantly reduced by applying these tools, whic are fundamental in the development of lighter, stronger, safer and more comfortable vehicles.
In addition to the complex simulations, Ricardo are constantly developing new analysis tools and techniques, offering value added analysis results interpretation to ensure rapid and efficient solutions to engineering problems. A dedicated, secure FTP site is available for data transfer between customer and Ricardo offices. Ricardo has expertise in the following FEA software tools: Hypermesh, Patran, MSC Nastran, Radioss, Pamcrash, LS-Dyna, Abaqus, Optistruct, Hyperworks, MSC Fatigue, Adams. The Vehicle Safety and Structural Analysis team also uses Ricardo Software packages.
The following vehicle components and sub-structures are analysed within the Vehicle Safety and Structural Analysis group: Body in white (BIW), trim, doors, hoods/bonnet, tailgate, sub-frame, steering, restraint system, suspension, brakes, powertrain/suspension mounting, exhausts/mufflers.
Ricardo has core FEA competences in the following analysis disciplines:
Vehicle Passive Safety Simulation
Vehicle structural integrity is paramount for meeting increasingly more stringent global safety legislation. Finite Element Analysis is an ideal simulation tool to predict and improve vehicle structures and restaint systems, reducing the time and expense of prototype crash testing. Ricardo has considerable experience in the field of vehicle safety and crash simulation tools including:-
- Simulation of front, rear, side, pole impact and roof crush tests to standard specification (EuroNCAP, ECE, FMVSS etc)
- Pedestrian impact simulation
- Airbags and knee bolster development
- Interpretation of regional safety legislation
- Planning and management of crash test programmes
Vehicle Structure Noise & Vibration Simulation
Customers are constantly demanding improved noise and vibration for passsenger and commercial vehicle applications. Ricardo apply FEA tools that can predict road and powertrain induced structural noise and vibration at the driver and passenger interfaces before any physical components or vehicles are constucted. Ricardo has developed a standard set of virtual test track load cases that simulate typical driving conditions. The following tools are extensively applied:-
- Full vehicle and body in white (BIW) modal analysis
- Frequency and time domain noise and vibration forced response analysis
- Modal participation, design sensitivity and structural optimisation methods
- Acoustic cavity noise simulation
- Modal assurance Criterion (MAC) correlation
- Exhaust structure shell noise simulation
- MSC Nastran/Adams mnf file conversion
The vehicle simulation team also work closely with the NVH testing department, who provide support for target setting and results interpretation.
Vehicle Component Strength and Fatigue Simulation
Durability simulation is key to ensuring a component reaches its expected life and is as light as possible. Ricardo has experience working with advanced simulation tools and new materials such as ultra high strength steels to achieve these goals. Optimisation tools are used to analyse loadpaths and define concept component shape and form with respect to stress and stiffness targets. More detailed models are then used to capture component interfaces and joints. Representative load and boundary conditions are fundamental, therefore Ricardo has developed comprehensive standard procedures and input functions. Tools can be applied to playback rreal road load inputs and generate a fatigue life pediction for individual parts. Manufacturing specialists can simulate forming processes and provide valuable information relating to areas of material thinning and work hardening for further optimisation of parts.
Examples of applied methods:-
- Structural optimisation and load path analysis
- Linear and non-linear simulation, including contact analysis
- Static and dynamic simulation
- Statis stiffness
- Buckling analysis
- Thermal and thermo-mechanics
- BIW and closure stiffness and strength
- Material and weld fatigue
- Roll over protection structures