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Guideline for Main Assignment

and Examples
AUTO1026/MIET2491 (Advanced CAE)

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Main Assignment (Auto1026 & MIET2491)
“Design & Analyse a FEM Model Using Beam Elements”

• Analyses: NVH (SOL103 & SOL111).

• A PDF report (<15 A4-pages, PDF) & a PPT presentation (~10 slides) must be
submitted via RMIT Learning Hub.

• You will give an oral PPT presentation of your CAE model and the results along
with the report.

Note: You need to search internet to find the estimated dimension of the car
that you are willing to use it for your main Assignment. See also the sample
projects in the Week-01 lecture notes in Learning Hub.
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How to find the vehicle BIW size
information

• You can search picture of Vehicle BIW with key words (search
keywords such as: Body In White, Chassis drawing, and blue prints)
on Google or other search engines.

• The following are some example types of drawing you can used as
reference to get the geometry of vehicle:

Type-1: Photo of vehicle BIW Type-2: Picture of CAD Model of Type-3: CAD Drawing of vehicle BIW
vehicle BIW

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How to create The ARC Line (Curve) in

Hypermesh Software
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How to create arc shape line in Hypermesh

In the vehicle concept model, some components (e.g. A-pillar, B-

pillar, and the roof) are in the shape of arc.
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Create line in arc shape using Hypermesh

Create nodes along a ark shape: Click “Geom” >>>>> Click “Nodes” >>> Enter
Coordinate >>>> Click “Create”.
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Create line in arc shape using Hypermesh

Click “Goem” >>>> Click “lines” >>>> Click “line nodes” >>>Click “Smooth Nodes”
>>>> Selected all the nodes one be one. >>>> Click “Create”
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Create line in arc shape using Hypermesh

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How to create 2D shell panels in

Hypermesh Software
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How to create 2D shell panel in Concept model

In the vehicle concept model, it is suggested to add the large panel

structures (e.g. windshield and roof).
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Create 2D shell element component in concept model

– Method 1
Click “2D” >>>> Click “Edit Element” >>>> Select “Tria” >>>>
Select three nodes to form a large element >>>> Click “Create”
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Create 2D shell element component in concept model

– Method 2
Click “Goem” >>>> Create Nodes >>>> Create Smooth Line
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Create 2D shell element component in concept model

– Method 2
Click “2D” >>>> Click “Skin” >>>> Select two parallel guide line
>>>> Click “Create”
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Create 2D shell element component in concept model –

Method 2
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Dimensions
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Methodology

1.To place nodes on car body from solid- 2. Obtain Coordinate of the
works. nodes.

4. 1-D and 2-D

MESHING. 3. Create Node and Reflect
Nodes
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The key Nodes Coordinates on the half of
BIW
• The sample of nodes locations are shown below with red
label.

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Obtain the coordinate of Nodes in BIW

• Set the original node (0, 0, 0) in the system.
• Using ruler to measure the coordinate of all the nodes
respect to the original nodes. (Unit: millimetre)

(0, 0, 0)

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Plot the nodes and lines in HyperMesh

• Enter all the nodes into Hypermesh
• Create line between these nodes, like picture below.

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Components
In this assignment, it is optional
to add shell elements to simulate
the large sheet metal components,
like roof, wind shield, and floor,
as the picture on the right hand
side shows.

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Beam Cross/Sections for this car.

You may use different cross/sections
for your own car.

In this Assignment, at least 10

components and cross-sections
are required.

20 or more Cross-sections are

recommended.
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Beam Section Orientation

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A Concept Model for a Compact SUV Car

(Example for your Main Assignment)
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Material Property
• Steel:

• Aluminium (Optional):

• Plastic (Optional):

• Glass (Optional):

• Carbon Fibre Reinforced Polymer (CFRP)

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Total Mass for this Car (Example)

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Model Geometry

▪ Nodes measured and scaled from SolidWorks chassis model.

▪ Photographs used as supplementary reference.

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Model Geometry

▪ 23 components used for 1D-beam elements.

▪ 3 materials – aluminium front & rear chassis, carbon fiber monocoque and glass.
▪ Total elements = 71147, total mass of 289kg.

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Modelling Connections

▪ Connections between the 1D-beam elements and the 2D-shell elements were modelled
as RBE2 rigid connections, with one master (independent) and multiple slave
(dependent) nodes to avoid singularities.

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Mode Shapes
Mode #1 – 60.2Hz Mode #2 – 61.4Hz

Mode #3 – 68.7Hz Mode #4 – 74.9Hz

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Previous Year Student Project: Example 1

• Student Name: Zhong Yang

• Car Model: Self Design

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AUTO1026/MIET2491 (Advanced CAE) Prof. M. FARD
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Geometry Design - CATIA Model

Geometric Design

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AUTO1026/MIET2491 (Advanced CAE) Prof. M. FARD
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Pro-Processing - CAE Model

CAE model

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AUTO1026/MIET2491 (Advanced CAE) Prof. M. FARD
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FEA Meshing and the Property Setting

FEA meshing and property setting

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AUTO1026/MIET2491 (Advanced CAE) Prof. M. FARD
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FEA Meshing and the Property Setting

Final Mesh
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AUTO1026/MIET2491 (Advanced CAE) Prof. M. FARD
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Results

Mode 7 is an Overall Torsion Mode Shape.

Mode 8 is an Overall Torsion Mode Shape.
Mode 9 is a Local (Front) Bending Mode Shape.
Mode 10 is a Local (Front) Bending Mode Shape.
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AUTO1026/MIET2491 (Advanced CAE) Prof. M. FARD
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Results

Mode 11 is an Overall Bending Mode Shape.

Mode 12 is a Local (Front) Roof Mode.
Mode 13 is a Local (Front) Roof Mode Shape.
Mode 14 is a an Overall Torsion Mode Shape.
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AUTO1026/MIET2491 (Advanced CAE) Prof. M. FARD
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Forced Vibration Analysis

The Distribution of The Input Point and The Output Point On Nodes

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AUTO1026/MIET2491 (Advanced CAE) Prof. M. FARD
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FRF Results

Input is in single point at node #2 in Z-axis.

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AUTO1026/MIET2491 (Advanced CAE) Prof. M. FARD
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FRF Results

AutoSEA2 software

Input is in points #2 & #22 in same phase (same direction in Z axis).

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AUTO1026/MIET2491 (Advanced CAE) Prof. M. FARD
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FRF Results

Input is in points #2 & #22 in opposite phase (opposite direction in Z axis).

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AUTO1026/MIET2491 (Advanced CAE) Prof. M. FARD
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Previous Year Student Project: Example 2

• Student Name: Hugh Miles

• Car Model: Toyota Kluger

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AUTO1026/MIET2491 (Advanced CAE) Prof. M. FARD
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CAE Model

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AUTO1026/MIET2491 (Advanced CAE) Prof. M. FARD
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Model Progression

• Added roof panel

• Added windscreen

• Added members to
radiator support area

• Added strut towers

• Added firewall
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AUTO1026/MIET2491 (Advanced CAE) Prof. M. FARD
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Model Results

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AUTO1026/MIET2491 (Advanced CAE) Prof. M. FARD
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FRF Results - In Phase Excitation

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AUTO1026/MIET2491 (Advanced CAE) Prof. M. FARD
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FRF Results - Out of Phase Excitation

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AUTO1026/MIET2491 (Advanced CAE) Prof. M. FARD
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FRF Results - Lateral Input

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AUTO1026/MIET2491 (Advanced CAE) Prof. M. FARD
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Last Year CAE Student Project: Example 3

• Student Name: Ivan Stevanovic
• Car Model: Ford GT40

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AUTO1026/MIET2491 (Advanced CAE) Prof. M. FARD
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Model Development (SolidWorks)

• Use of CAD Software SolidWorks

images of Ford GT40 were imported.
➢ Dimensions used for the Frame

The dimensions of the vehicle frame:

Width: 1778 mm
Height: 915 mm
Length: 4040 mm

• Ford GT40 geometry was created using

lines to represent the beam locations.
• Relative points obtain for input into
HyperMesh.

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AUTO1026/MIET2491 (Advanced CAE) Prof. M. FARD
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Model Development (HyperWorks)

• Created 228 temporary nodes

• Created Components and 18 Properties
• Created lines for the beams using Component
specifications
• Created 22 beam cross-sections
• Created a Mesh for Beam and Shell elements
➢ Shell: Use Spline and selected the required
lines

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AUTO1026/MIET2491 (Advanced CAE) Prof. M. FARD
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Model Development (HyperWorks)

Material Selection:

• Steel (ZE 50/50 zinc coated mild steel)

for beam sections and shell sections
Young’s Modulus (E) = 2.1e8
Poisson Ratio(Nu) = 0.303
Density (RHO) = 7.8e-6
Structural Damping (GE) = 0.01

• Aluminium (6061 T6) for beam sections

and shell sections
Young’s Modulus (E) = 7.2e7
Poisson Ratio(Nu) = 0.35
Density (RHO) = 2.7e-6
Structural Damping (GE) = 0.03

• Glass for shell section of windshield

Young’s Modulus (E) = 7.0e7
Poisson Ratio(Nu) = 0.22
Density (RHO) = 2.3e-7
Structural Damping (GE) = 0.01

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AUTO1026/MIET2491 (Advanced CAE) Prof. M. FARD
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Model Development

Concept Modelling of cast pieces

• Original suspension mounts are a

complex honeycomb structure.
• Modelled suspension mounts
created using:
➢ Beam Elements
➢ Shell Elements Beam and Shell replacement for
Cast suspension mounts
Honeycomb
Structure

Beam Size
(25x25x2mm)

FE Model
representation of
honeycomb
Shell Thickness
structure
(2mm)

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AUTO1026/MIET2491 (Advanced CAE) Prof. M. FARD
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Modal (Normal Modes) Analysis (SOL 103)

• Typical frequency ranges for Mode Frequency Mode shape

standard road vehicles is defined Number (Hz) Deformation
in the table below. 1st Order
7 63.34
Bending
Frequency Range 2st Order
Vehicle Component 8 74.19
(Hz) Bending
Suspension 5-15 1st Order
Tyre modulation 0-30 9 75.40
Torsion
Power train 0-12 2nd Order
Body 20-32 10 79.54
Torsion
Steering 25-35 3rd Order
Seats 15-25 11 97.77
Torsion
𝑅𝑜𝑡𝑎𝑡𝑖𝑜𝑛𝑎𝑙 𝑆𝑝𝑒𝑒𝑑(𝑟𝑝𝑚) 4th Order
𝐹𝑟𝑒𝑞𝑢𝑒𝑛𝑐𝑦 𝐻𝑧 = 𝑁 × 12 101.60
60(𝑠𝑒𝑐) Torsion
N (Order of rotation for a V8) = 4
Rotational Speed (idle) = 700 rpm

• Ford GT40 engine idle frequency using a

V8 was calculated to be 46.67 Hz.

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AUTO1026/MIET2491 (Advanced CAE) Prof. M. FARD
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Modal (Normal Modes) Analysis (SOL 103)

Mode Shapes (0-100Hz)

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AUTO1026/MIET2491 (Advanced CAE) Prof. M. FARD
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Input Point

Modal Frequency Response Function (FRF)

• Input Points were selected Input Point

to be at the front and rear Output Point
suspension mounts as
these are subjected to the
largest frequency range.

• Output Points were

selected at the 4 seat
mounts. This was done to
identify the frequency
response at the occupant
location in the vehicle. • The front suspension mounts above demonstrate
In Phase load application (Bending modes)

• The rear suspension mounts above demonstrate

Out of Phase load application (Torsional modes)

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AUTO1026/MIET2491 (Advanced CAE) Prof. M. FARD
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Modal Frequency Response Function (FRF)

In Phase

Front Suspension
Mounts

Rear Suspension
Mounts

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AUTO1026/MIET2491 (Advanced CAE) Prof. M. FARD
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Modal Frequency Response Function (FRF)

Out of Phase

Front Suspension
Mounts

Rear Suspension
Mounts

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AUTO1026/MIET2491 (Advanced CAE) Prof. M. FARD
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Example 4

• Student Name: Athos Nobile

• Car Model: Ford Mustang Coupe

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AUTO1026/MIET2491 (Advanced CAE) Prof. M. FARD
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FEA Model Build
Geometry

• Scaled 1:1

Dimension Actual Car Model

Length 4783 mm 4405 mm
Height 1382 mm 1048 mm
Width - Exc mirrors 1915 mm 1914 mm

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AUTO1026/MIET2491 (Advanced CAE) Prof. M. FARD
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FEA Model Build
Geometry

• Built in AutoCAD from 2D images

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23/07/2015 AUTO1026/MIET2491 (Advanced CAE) Prof. M. FARD
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FEA Model Build
Geometry

• Half car made in 3D, then mirrored

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AUTO1026/MIET2491 (Advanced CAE) Prof. M. FARD
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FEA Model Build

Geometry

• Curved surfaces added, exported as .IGS

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AUTO1026/MIET2491 (Advanced CAE) Prof. M. FARD
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FEA Model Build

FEA Model

• Import geometry & define components (27)

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AUTO1026/MIET2491 (Advanced CAE) Prof. M. FARD
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FEA Model Build

FEA Model

• Define materials (3): Steel, Aluminium, Glass

• Create beam sections (23) & properties (28)

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AUTO1026/MIET2491 (Advanced CAE) Prof. M. FARD
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FEA Model Build

FEA Model

• Mesh model and assign properties

• Mesh size: 10 mm for PBEAM and 25 mm for PSHELL elements

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AUTO1026/MIET2491 (Advanced CAE) Prof. M. FARD
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FEA Model Build

FEA Model

• Join elements

• Calculate model mass

• Export solver deck, run & debug

Mass after section

revision: 352 Kg, Mass as initially
31% reduction and meshed: 513 Kg
close to real car’s
~345 Kg

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AUTO1026/MIET2491 (Advanced CAE) Prof. M. FARD
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FEA Model Build

FEA Model

• Calculate FRF on selected nodes

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Results

• FRF and modes identification

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Results

• FRF and modes identification

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Results

• BIW vibration modes

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AUTO1026/MIET2491 (Advanced CAE) Prof. M. FARD
Example 5: James McEnery (2020)
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Ford Focus Active, Hatchback Passenger Vehicle.

(The 2020 Ford Focus & Focus Active Small Car Range | Ford Australia, 2020)
.(New Ford Focus – Car Body Design, 2020).

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Method: (1) Node Creation. (2) Component Line Creation.

Model
Construction.

(4) Component 2D Shell Mesh.

(3) Component 1D Beam Mesh.

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Results:

Modal Analysis.

FRF: Single Node

Input

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Results:

Modal Analysis.

FRF: In Phase
Input.

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Other Examples

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Jacky Ngo (Aston Martin)

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Rixin Li (Mazda 3)

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Siyamak Ziyaei (Ford Falcon)

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Peter Neumann (Honda N-One)

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Airplane by: Cooper Robert Swann (2021)

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