CDTire: State-of-the-art Tire Models for Full Vehicle Simulation

2012 Americas HyperWorks Technology Conference Dr. Manfred Bcker, Axel Gallrein

Fraunhofer ITWM 1

Fraunhofer Society
Itzehoe Rostock

Fraunhofer Society 2010 Non-profit 60 institutes 18 000 employees 1.65 bill. Euro

Lbeck Bremerhaven Bremen Hannover Braunschweig Paderborn Dortmund Oberhausen Duisburg Schmallenberg Potsdam Magdeburg Halle Schkopau Cottbus Leipzig Berlin Teltow

Fraunhofer ITWM Dresden Sankt Augustin Erfurt 220 employees Aachen Jena Chemnitz Ilmenau Euskirchen 18 mill. Euro Darmstadt Wrzburg Transport, fluid and Erlangen material simulation Kaiserslautern St. Ingbert Frth Dynamics and durability Nrnberg Saarbrcken Karlsruhe Pfinztal Image processing Stuttgart Freising Optimization Freiburg Mnchen Finance Oberpfaffenhofen EfringenHigh performance computing Holzkirchen Kirchen
Fraunhofer ITWM 2

Agenda
Overview CDTire Model Family Parameterization How CDTire works with MotionSolve Introducing new models CDTire 30/HPS CDTire 50 On-going developments CDTire NVH Tire / soil interaction
Fraunhofer ITWM 3

Tire Simulation in Vehicle Development

Driver model
Open loop Closed loop Optimal control

Vehicle model
MBD model FEA model Subsystems

Tire model
MBD model FEA model Linearization

Road model
Rigid surface Soil Multi pass

Fraunhofer ITWM 4

MBD Tire Models - - - - vs. - - - Application Fields

DOFs 100 Typical computational effort 101 REPs

Empirical Frequency-based

Handling

103 Typical number of simulations

NVH Active safety

102

102

Rigid ring Emperical contact Ride/Comfort Flexible belt Brush-type contact FEA
101

103

104 105

Durability

Crash

100

Fraunhofer ITWM 5

MBD Tire Model Family CDTire

DOFs 100 Typical computational effort 101 REPs

Empirical Frequency-based

Handling

103 Typical number of simulations

NVH Active safety

102

102

Rigid ring Emperical contact Flexible belt Brush-type contact FEA

CDTire 20

Ride/Comfort
103 CDTire 30 CDTire 40 CDTire MC 101

104 105

Durability

TireTool

Crash

100

Fraunhofer ITWM 6

MBD Tire Model Family CDTire

Model 20 Rigid ring Physical tangential contact formulation Model 30 Flexible ring Brush type contact Model 40 Flexible Belt Independent sidewalls Model MC Large belt curvature Large inclination angles
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Adaptive models (automatic switching) Model 2030 Model 2040

CDTire 20
Model details Rigid ring Physical tangential contact formulation Road surfaces Arbitrary 3D Long wavelength Typical applications
Belt point

Active safety Real-time factor 3-6

Tread height
Surface point

Lateral direction

Handling (Durability)

Belt velocity Shear deformation

cY

cX
Longitudinal direction

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CDTire 20: Application Scenario Handling

Publication Yang, X., Medepalli, S.: Comfort and Durability Tire Model Validation, Tire Science and Technology, TSTCA, Vol. 37, No. 4, October December 2009, pp. 302-322.

Fraunhofer ITWM 9

CDTire 30
Model details Flexible ring Brush type contact formulation Accumulated sidewall Road surfaces Trackwise 2D Arbitrary wavelength Typical applications Ride & Comfort Durability Real-time factor 10 - 30
Fraunhofer ITWM 10

CDTire 30: Application Scenario Durability

Publication Sawa, N., Nimiya, Y., Kubota, Y., Itsubo, T. et al., "Fatigue Life Prediction on Rough Road Using Full Vehicle Cosimulation Model with Suspension Control," SAE Technical Paper 2010-010952, 2010, doi:10.4271/2010-01-0952.

Full vehicle rough road run

Full vehicle cleat run

Fraunhofer ITWM 11

CDTire 40
Model details 3D structure Brush type contact formulation Independent sidewalls Road surfaces Arbitrary 3D Typical applications Ride & Comfort Durability Real-time factor 40 - 100

Fraunhofer ITWM 12

CDTire 40: Application Scenario Special Events

Publication Baecker, M., Gallrein, A., and Haga, H., "A Tire Model for Very Large Tire Deformations and its Application in Very Severe Events," SAE Int. J. Mater. Manuf. 3(1):142-151, 2010, doi:10.4271/2010-010373.

Fraunhofer ITWM 13

CDTirePI: Parameterization via Measurements

Measurements Geometry (cross section, foot print) Modal analysis Static (stiffnesss, on cleat) Steady-state (long. + lateral slip) Transient (90+45 cleat runs) Optimization schemes Local Fuzzy (expert knowledge build into rule sets)

Fraunhofer ITWM 14

TireTool: Parameterization via FEA tire model

Layer 1: Exp. Data Material Modal Analyze Stiffness Cleats Geometry Footprints Ground-out

Virtual measurement

Layer 2: Parameter Identification

Local structure properties

Layer 3: Application Crash

Fraunhofer ITWM 15

Misuse

NVH

Special Events

Durability

Handling

TireTool: Parameterization via FEA tire model

Cross section 2D model 3D model Virtual measurements

Cross section scan Contour measurement

CT-Scan cords Tire weight Shore A

Modes and frequencies Static stiffnesss

Cleat runs Ground-out

Fine tune

Fraunhofer ITWM 16

TireTool: Parameterization via FEA tire model

Measurements Geometry (cross section, foot print) Modal analysis Static (vertical stiffness) Material CT Output is Abaqus model

Fraunhofer ITWM 17

Tire-Tool: Parameterization via FEA tire model

90 cleat run 40x40mm, 11 km/h, CDT40 validation
Longitudinal Force
4000 3000 2000 1000
Force [N]
Measurement Simulation

LDE test rig @ Fraunhofer Kistler P530 hub Max. 12 km/h Max. Fz 30 kN Up to rim contact

0 -1000 -2000 -3000 -4000 -5000

5.1 5.15 5.2 5.25 5.3 5.35 5.4 5.45 5.5

Time [s]

Vertical Force
30000 25000 20000
Force [N]
Measurement Simulation

15000 10000 5000 0

5.1 5.15 5.2 5.25 5.3 5.35 5.4 5.45 5.5

Time [s]

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Tire-Tool: Parameterization via FEA tire model

90 cleat run 40x40mm, 11 km/h (FEA validation), 30 and 40 km/h (prediction)

Fraunhofer ITWM 19

TireTool: Parameterization via FEA tire model

3D continuum
Reissner-Mindlin hypothesis

2D shell

FEM

Reduction of degrees-of-freedom (dofs) Proper orthogonal decomposition (POD) BMBF joint project Multi-disciplinary Simulation and Non-linrear Model Reduction (SNiMoRed)

Fraunhofer ITWM 20

FEM

(CDTire 50)

How CDTire works with MotionSolve

Cooperation Altair / Fraunhofer Altair is exclusive reseller for CDTire4MotionSolve Distributed with HyperWorks 11.0 Integrated visual support in development Tire models 20 / 30 / 40 / 2030 / 2040

Road models RSM1000 (parametric obstacles) RSM1002 (drum model) RSM2000 (large digital data) RSM3000 (OpenCRG) RSM1100 (User API) Full .adm compatibility Full CDTire.ini support (parallelization)

Fraunhofer ITWM 21

Introducing new models

New developments
Model 20 Rigid ring Physical tangential contact formulation Model 30 Flexible ring Brush type contact Model 40 Flexible Belt Independent sidewalls Model MC Large belt curvature Large inclination angles
Fraunhofer ITWM 22

Model 30/HPS C/C++ High Performance Solver Real-time capable Model 50 Materialized sidewalls Geometrical non-linear elastic shell discretization Model NVH Flexible rim Cavity mode

Introducing new models

Application scenarions
Model 30/HPS MIL / SIL / HIL cascade Vehicle performance optimization Model 50 Large deformation, ground-out Handling on rough road Model NVH Up to 300 Hz

New developments
Model 30/HPS C/C++ High Performance Solver Real-time capable Model 50 Materialized sidewalls Geometrical non-linear elastic shell discretization Model NVH Flexible rim Cavity mode

Fraunhofer ITWM 23

CDTire 30/HPS
Master integrator (typically larger time steps) Iteration scheme Step size control Slave integrator (typically smaller time steps) Iteration schemes (HPS: PECE, Newmark) Master step size control Tunable controls: Secured time step Master iteration Slave iteration t Slave step size dt = minor step of tire model
integrator Dt = MBS step size new time step to be calculated by MBS-solver

dt Integrates tire states from t -> t+Dt using much smaller minor steps dt

t+Dt

time

MBS-solver

Estimated rim states at t+Dt

Tire model solver

Tire forces at t+Dt

Fraunhofer ITWM 24

CDTire 30/HPS
Scenario: 4 cleats (20x20mm), 40 km/h, 3 sec C/C++ High Performance Solver Efficient memory storage and access Efficient implicit Newmark with special projector in Newton-Iteration Choice of deterministic integrator settings (fixed step, fixed iterations) Parallelizable incl. road surface models (OpenCrg, RSM2000, RSM1000)
New CDT30 model. 100 MP 10000

5000

CDT30 (explicit integrator) Real time factor = 1.8 CDT30/HPS (explicit integrator) Real time factor = 1.1

Fx, N 0 -5000

0.8

1.2

1.4

1.6

1.8

2.2

2.4

2.6

9000 8000 Fz, N 7000 6000 5000

CDT30/HPS (implicit integrator, var. step) Real time factor = 0.6 CDT30/HPS (implicit integrator, determ.) Real time factor = 0.8

0.8

1.2

1.4

1.6 Time, s

1.8

2.2

2.4

2.6

Fraunhofer ITWM 25

CDTire 30/HPS: Application Scenario Test Rig

Scenario MIL / SIL / HIL: Implementation used as component on real test rigs Road profile and driving rule can be used as excitation of the test rig No test track measurement needed (usually used as target for iteration process)

Fraunhofer ITWM 26

CDTire 30/HPS: Application Scenario Drive Simul.

Scenario MIL / SIL / HIL: Component in Drive Simulator VAR-Simulator (Versatile Augmented Reality)

Fraunhofer ITWM

Fraunhofer IGD & ITWM

Fraunhofer FIRST

Fraunhofer ITWM

Graphics cluster with scene graph

Warping, edge blending, color & contrast calibration

Spherical screen 10m diameter 300 * 110 FOV

Vehicle CAD data

18 synchronal WUXGA projectors 3D scenery 3D terrain data Real-time PC HMI data robot states

Motion tracking

Fraunhofer ITWM 27

CDTire 50
Functional element modeling Element stacking in pre-processing FD shell discretization

Belt Sidewall Rim

Fraunhofer ITWM 28

CDTire 50
Scenario: 18 cleats (10x10,,20x20mm), 40 km/h, 10 sec C/C++ High Performance Solver Efficient memory storage and access Efficient implicit Newmark with special projector in Newton-Iteration Choice of deterministic integrator settings (fixed step, fixed iterations) Parallelizable incl. road surface models (OpenCrg, RSM2000, RSM1000)

CDT50 (explicit integrator) 50 cross sections 12 segments Real time factor = 49

Fraunhofer ITWM 29

CDTire NVH
Method NVH FEA tire Steady state transport analysis (relative kinematic ALE description) Internal Fraunhofer research project (MEF) Cavity possible Flexible rim possible

Rim and road (footprint) excitation

Condensation of road excitation: Track-wise time delay as phase shift

Z Y X

apply vertical load on inflated tire ODB: 03_tire_loading.odb Abaqus/Standard 6.10EF2 Step: Loading0 Increment 22: Step Time = 0.9650 Deformed Var: U Deformation Scale Factor: +1.000e+00

Fri Jul 08 10:49:32 CEST 2011

Fraunhofer ITWM 30

CDTire NVH
Internal Fraunhofer research project (MEF) Linearization around Stationary rolling state Transient Equations of motion Add Gyroscopic forces Linear State space equation Laplace Transform Condensation of Road excitation Solver independence Linearization and Transient

Fraunhofer ITWM 31

CDTire NVH
Switch to eulerian description by adding gyroscopic forces Leads to frequency split for rotating tires Example is free hanging tire, but rotating

Residual force

Fraunhofer ITWM 32

CDTire NVH
Simulated experimental modal analysis Spacial acceleration measurement Free rim, constant rot. velocity w = 85 rad/s

Counter

Inphase

Fraunhofer ITWM 33

Tire / Soil interaction

No deformation Rigid surface Local deformation, decoupled Terrain response Local deformation, coupled Bulldozing effect Terrain compaction Multipass Tangential mass transport Slip sinkage Diskrete Element Method DEM

Fraunhofer ITWM 34

Tire / Soil interaction

Simple pressure-sinkage relations Bekker: p(z) = (kc/b + k)zn Reece: p(z) = (c c + s b )(z/b)n (kc,k,c,,n: pressure-sinkage parameters, s: weight density, c: cohesion of terrain) Instantaneous soil deformation No sinkage propagation Localized parameter, i.e. k = k(x,y), n = n(x,y) Tangential frictional contact Implementation in C/C++ Python interface for rapid evaluation of alternative sinkage models

Fraunhofer ITWM 35

Spreading the Application Range

DOFs 100 Typical computational effort 101 REPs

Empirical Frequency-based
CDTire NVH

Handling

103 Typical number of simulations

NVH Active safety

102

102

CDTire 20

Rigid ring Emperical contact Flexible belt Brush-type contact FEA

CDTire 30 CDTire 40 CDTire MC CDTire HPS CDTire 50 TireTool

Ride/Comfort
101

103

104 105

Durability

Crash

100

Fraunhofer ITWM 36

CDTire: State-of-the-art Tire Models for Full Vehicle Simulation

2012 Americas HyperWorks Technology Conference Dr. Manfred Bcker, Axel Gallrein manfred.baecker@itwm.fraunhofer.de axel.gallrein@itwm.fraunhofer.de

Thank you for your attention !

Fraunhofer ITWM 37