CAE analysis of a conrod for motorbike application

R. Testi (riccardo.testi@piaggio.com)
Piaggio & C. SpA – Italy (www.piaggio.com)

ANSYS Conference & 26th CADFEM Users´ Meeting

 Presentation outline

• Company profile
• Object of the study
• Analysis methodology
• Results
• Synopsis

ANSYS Conference & 26th CADFEM Users´ Meeting

 Company profile – Piaggio Group

Business areas

2-wheelers

Light Transport
Vehicles

Engines

Spare parts
and accessories

ANSYS Conference & 26th CADFEM Users´ Meeting

 Company profile – Piaggio Group

Brands managed

ANSYS Conference & 26th CADFEM Users´ Meeting

 Company profile – Piaggio Group

A few figures

• one of the world’s top four manufacturers of two-wheel motor

vehicles
• consolidated leadership position on the European 2-wheeler
market
• approximately 7,000 employees
• facilities: Pontedera (Pisa-Italy); Scorzè (Venice-Italy);
Mandello del Lario (Lecco-Italy); Barcelona (Spain); Baramati
(India)
• R&D centres: Italy, Spain, China and India
• vehicle sold in 2007: 708,500
• net sales in 2007: 1,692 million Euro

ANSYS Conference & 26th CADFEM Users´ Meeting

 Presentation outline

• Company profile
• Object of the study
• Analysis methodology
• Results
• Synopsis

ANSYS Conference & 26th CADFEM Users´ Meeting

 Object of the study
New 1200 cc
Aprilia Shiver twin engine

Max power 103 kW

Conrod Max torque 120 Nm

Prediction of fatigue
performance
ANSYS Conference & 26th CADFEM Users´ Meeting
 Presentation outline

• Company profile
• Object of the study
• Analysis methodology
• Results
• Synopsis

ANSYS Conference & 26th CADFEM Users´ Meeting

 Analysis methodology

Geometry ANSYS/Workbench

CAD software
Inertia
propertie
s
Dynamic
Static Load/stres
stresses s transfer
functions
MBS software

Load time-
Durability software
histories

Safety factor

ANSYS Conference & 26th CADFEM Users´ Meeting

 ANSYS/Workbench analyses

ANSYS/Workbench

Nonlinear Linear

Dynamic
Static Load/stres
stresses s transfer
functions

ANSYS Conference & 26th CADFEM Users´ Meeting

 ANSYS/Workbench nonlinear static analysis

Frictional contacts with interference Bolt pretensions

ANSYS Conference & 26th CADFEM Users´ Meeting

 ANSYS/Workbench analyses

ANSYS/Workbench

Nonlinear Linear

Dynamic
Static Load/stres
stresses s transfer
functions

ANSYS Conference & 26th CADFEM Users´ Meeting

 ANSYS/Workbench linear static analysis (1/2)
Unit magnitude bearing loads

Cylindrical joints

Unit loads at conrod’s interfaces

ANSYS Conference & 26th CADFEM Users´ Meeting

 ANSYS/Workbench linear static analysis (2/2)

One load per step

Stepped Static
Structural analysis

Inertia relief on

RST file’s structure

Loadstep Content
1 Bearing load #1
2 Bearing load #2 Ready to be coupled with
… … load time-histories

ANSYS Conference & 26th CADFEM Users´ Meeting

 Analysis methodology

Geometry ANSYS/Workbench

CAD software
Inertia
propertie
s
Dynamic
Static Load/stres
stresses s transfer
functions
MBS software

Load time-
Durability software
histories

• Stress tensor
• Safety factor

ANSYS Conference & 26th CADFEM Users´ Meeting

 ANSYS/Workbench analyses

ANSYS/Workbench

Nonlinear Linear

Dynamic
Static Load/stres
stresses s transfer
functions

Same node/element numbering

Requirement for durability analysis

ANSYS Conference & 26th CADFEM Users´ Meeting

 ANSYS/Workbench analyses – dummies to keep same numbering

Linear

Dummies to
keep the
PRETS179s
Workbench

Dummies to Nonlinear
keep the
SURF154s

ANSYS Conference & 26th CADFEM Users´ Meeting

 Analysis methodology

Geometry ANSYS/Workbench

CAD software
Inertia
propertie
s
Dynamic
Static Load/stres
stresses s transfer
functions
MBS software

Load time-
Durability software
histories

• Stress tensor
• Safety factor

ANSYS Conference & 26th CADFEM Users´ Meeting

 MBS analysis (1/2)
Bench test conditions Testrig rotary inertia

Gearbox

Gas forces

ANSYS Conference & 26th CADFEM Users´ Meeting

 MBS analysis (2/2)

Combined with
load/stress TF by
durability SW

Gas forces Longitudinal forces on conrod #2

— Conrod #1 --Conrod #2 — Big eye --Small eye
ANSYS Conference & 26th CADFEM Users´ Meeting
 Analysis methodology

Geometry ANSYS/Workbench

CAD software
Inertia
propertie
s
Dynamic
Static Load/stres
stresses s transfer
functions
MBS software

Load time-
Durability software
histories

• Stress tensor
• Safety factor

ANSYS Conference & 26th CADFEM Users´ Meeting

 Durability analysis (1/2)

Dummy unit time-histories for static loads

Workbench MBS

Load/stress Load time-history

transfer functions
Stress tensor
X = time-history

ANSYS Conference & 26th CADFEM Users´ Meeting

 Durability analysis (2/2)
Model structure
FEM results

Linear combinations

MBS results
Solver parameters

ANSYS Conference & 26th CADFEM Users´ Meeting

 Presentation outline

• Company profile
• Object of the study
• Analysis methodology
• Results
• Synopsis

ANSYS Conference & 26th CADFEM Users´ Meeting

 Results (1/3)
Safety factor vs. endurance limit

SOUND CONROD DESIGN

1.25

Minimum allowable value according to

Piaggio standards

ANSYS Conference & 26th CADFEM Users´ Meeting

 Results (2/3)

Omitting given load channel

Most damaging load

ANSYS Conference & 26th CADFEM Users´ Meeting

 Results (3/3)
TDC – start of power stroke

Most severe condition

ANSYS Conference & 26th CADFEM Users´ Meeting

 Presentation outline

• Company profile
• Object of the study
• Analysis methodology
• Results
• Synopsis

ANSYS Conference & 26th CADFEM Users´ Meeting

 Synopsis
Combined use
CAE of different
assessment of tools
critical
New engine components
(crankshaft,
crankcase,
conrod, ...)

Thank you for your

patience!
Load/stress TF Central role of
computation ANSYS/Workbench

Both linear and nonlinear models

Inertia relief Design soundness proved by
Compatiblity with other SW by ensuing durability analysis
dummy outline branches

ANSYS Conference & 26th CADFEM Users´ Meeting