Abstract
Today, complex seal systems are necessary to meet the high requirements of body seals in vehicles. The main tasks of seals include but are not limited to the protection against the intrusion of water into the passenger cabin or the channeling of rain water. Furthermore, the sound level in the interior should be as low as possible and turbulences at the side panels have to be prevented.
There is the challenge of reducing the development time as well as increasing the quality of the product. In order to achieve these aims, computer-aided methods and tools are applied to the product development process. Frontloading is used to define the product specifications as early as possible in the early phase of product development. In the context of developing seal systems the use of simulation methods, in particular the finite elements method, is essential. This method allows the representation and evaluation of the deformations and resulting forces on seals. Thus, weaknesses and risks of the developed seals may be shown already in the concept phase. The application of FEM analysis provides an important contribution to increase the virtual data quality and the computer-aided validation of properties.
The industrial partner calculated seal systems by FEM simulations based on 2D cross-sections so far. But some cases of applications are complex and a 3D consideration of the problem is needed. With the use of 3D FEM analysis, it is possible to extend the scope of engineering seals. One advantage of a 3D simulation compared to its 2D counterpart is the consideration of the overall seal system. Another benefit is the calculation of complex geometries, when 2D simulations are not able to solve the problem.
By three examples, which are typical for the automotive industry, the benefits of 3D FEM analysis of deformations compared to 2D FEM analysis are determined. The behavior of seal systems when deforming is rated and the potentials are evaluated.
First, the influence of discretization and the accuracy of the solution of a glass-run-seal are considered. Another simulation observes the deformation of a geometric complex part, namely the roof seal of a cabriolet at the c-pillar. By representing the deformed geometry, the correct contact face and the seal tightness can be determined. The last simulation computes the force of closing a front door. Due to curvature the edge protection seal deforms and leads to a different force. The influence of this curvature on the force is analyzed and the additional costs of a 3D simulation compared to a 2D simulation are evaluated.
3D FEM simulations of seals can reveal problems and weaknesses of seal systems already in the engineering phase of engineering. Even complex geometries are possible to calculate. Quick testings of different alternatives of materials, shapings and coefficients of friction are possible. This can lead to a shorter development time and cost cuts because expensive physical prototyping can be reduced
There is the challenge of reducing the development time as well as increasing the quality of the product. In order to achieve these aims, computer-aided methods and tools are applied to the product development process. Frontloading is used to define the product specifications as early as possible in the early phase of product development. In the context of developing seal systems the use of simulation methods, in particular the finite elements method, is essential. This method allows the representation and evaluation of the deformations and resulting forces on seals. Thus, weaknesses and risks of the developed seals may be shown already in the concept phase. The application of FEM analysis provides an important contribution to increase the virtual data quality and the computer-aided validation of properties.
The industrial partner calculated seal systems by FEM simulations based on 2D cross-sections so far. But some cases of applications are complex and a 3D consideration of the problem is needed. With the use of 3D FEM analysis, it is possible to extend the scope of engineering seals. One advantage of a 3D simulation compared to its 2D counterpart is the consideration of the overall seal system. Another benefit is the calculation of complex geometries, when 2D simulations are not able to solve the problem.
By three examples, which are typical for the automotive industry, the benefits of 3D FEM analysis of deformations compared to 2D FEM analysis are determined. The behavior of seal systems when deforming is rated and the potentials are evaluated.
First, the influence of discretization and the accuracy of the solution of a glass-run-seal are considered. Another simulation observes the deformation of a geometric complex part, namely the roof seal of a cabriolet at the c-pillar. By representing the deformed geometry, the correct contact face and the seal tightness can be determined. The last simulation computes the force of closing a front door. Due to curvature the edge protection seal deforms and leads to a different force. The influence of this curvature on the force is analyzed and the additional costs of a 3D simulation compared to a 2D simulation are evaluated.
3D FEM simulations of seals can reveal problems and weaknesses of seal systems already in the engineering phase of engineering. Even complex geometries are possible to calculate. Quick testings of different alternatives of materials, shapings and coefficients of friction are possible. This can lead to a shorter development time and cost cuts because expensive physical prototyping can be reduced
Translated title of the contribution | Examination of 3D-FEM-simulations by analyzing seal systems |
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Original language | German |
Qualification | Master of Science |
Awarding Institution |
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Supervisors/Advisors |
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Award date | 26 Apr 2016 |
Publication status | Published - Apr 2016 |