Ford Alloy Wheel Plant designs and manufactures cast alloy road wheels for the automotive industry using state of the art computer simulation facilities as part of the Ford Motor Companies world wide C3P* programme. Sinclair Knight Merz’ Structural Dynamics group were invited to complete a project of design analysis of a Mazda styled wheel being manufactured by Ford.
Extensive experience in both Computer Aided Engineering (CAE) and Finite Element Analysis (FEA) on the core software platform of Ford’s C3P programme, I-DEAS Master Series, allowed swift and accurate execution of the project tasks. Phases of the analysis included linear static solution of 800,000 degree of freedom solid models for detailed stressing, and production of FE models for complex downstream analysis including modal analysis and fatigue assessment.
Preparation of FE models incorporated multiple property specifications to allow material surface finishes to be defined throughout the FE mesh, for use during future casting simulation analysis. FE models were also translated to MSC/Nastran to facilitate the clients needs for multi-platform analysis.
Comprehensive testing programmes carried out by Ford in accordance with SAE guidelines routinely affirmed the results from the analytical simulations. With such dependable correlation and thus high confidence in the simulation process, dramatic cost reductions in test programmes can be achieved.
At project completion Ford were in a position to embark on five individual CAE phases all from the one FE model. The ability to carry out design in this manner maximises the efficiency of the entire design process.
*C3P - Ford Motor Company Computer Aided Design, Engineering, Manufacture and Product Data Management.