Influence of model reduction techniques on the impact force calculation of two flexible bodies

One important issue for the simulation of flexible multibody systems is the reduction of the flexible body's degrees of freedom. For the reduction process finite element data and user inputs are necessary. The model reduction program for elastic multibody systems MOREMBS, which is developed at the ITM, has an easy-to-use interface and the data can be gained from the programs ABAQUS or ANSYS. In this work, the simulation of a fuel injection process is investigated with MOREMBS. We focus on the interaction between valve and armature. These two bodies impact in every injection circle. The impacting bodies are modeled as flexible and the contact force is calculated by a penalty approach. One essential part of this work is the investigation of the influence of different model reduction techniques on the impact force calculation of the flexible multibody system. The main reduction techniques modal reduction, Krylov-subspace based and Gramian matrix based techniques are compared. The results achieved with modal reduction, the state of the art reduction method, are not acceptable here. Krylov-subspace based techniques are especially well-suited for large sparse systems but are not error controlled. However, by choosing appropriate moment-matching properties the impact force calculation is nearly as good as with a full finite element model. The Gramian matrix based reduction techniques can be fully automated and are error controlled but require high computational effort. Hence, appropriate approximation schemes have to be used for them. With Gramian matrix based methods we can even further reduce the size of the subsystems compared to Krylov-subspace based methods and still have an impact force calculation nearly as good as with finite element results, but we gain a simulation speedup by the factor 4000. In addition, a parameter study of the parameters involved in the model reduction process is presented. (© 2009 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim)     

A-posteriori error estimation for second order mechanical systems

One important issue for the simulation of flexible multibody systems is the reduction of the flexible bodies degrees of freedom.As far as safety questions are concerned knowledge about the error introduced by the reduction of the flexible degrees of freedom is helpful and very important.In this work,an a-posteriori error estimator for linear first order systems is extended for error estimation of mechanical second order systems.Due to the special second order structure of mechanical systems,an improvement of the a-posteriori error estimator is achieved.A major advantage of the a-posteriori error estimator is that the estimator is independent of the used reduction technique.Therefore,it can be used for moment-matching based,Gramian matrices based or modal based model reduction techniques.The capability of the proposed technique is demonstrated by the a-posteriori error estimation of a mechanical system,and a sensitivity analysis of the parameters involved in the error estimation process is conducted.     

Simulation of Force Transmission in Vehicle Steering Systems

This contribution proposes an approach, how the problem of a moving load on an elastic, beam–like body in an elastic MBS can be solved. Thereby a so–called moving interface marker is used. This marker can move along the bending line of the elastic, beam–like body and locates the point where the moving load is applied. With its help, the moving load can be transformed to forces and torques that have to be applied at the adjoining body–fixed interface markers. These calculated forces and torques lead to an identical deformation of the beam. (© 2008 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim)     

Improving the dynamic stability of a workpiece dominated turning process using an adaptronic tool holder

In this contribution, inside turning of a thin-walled cylinder is investigated in simulation. Self-excited vibrations can arise due to repeated cutting of the same surface, that lead to instability. A flexible multibody system model of the system is the basis for a subsequent analysis of the stability of the process. Stability analysis is done using an approximation as a time-discrete system via the semi-discretization method. An adaptronic turning chisel comprising a piezo actuator and sensors is then used in combination with different control concepts to improve the stability of the process. The effectiveness of the different strategies is compared based on the influence on the stability charts. A classic H_∞ controller based on a model of the coupled system of workpiece and tool can only yield some improvements, when an additional measurement of the workpiece displacement is added. Incorporating knowledge on the cutting process coupling workpiece and tool using a gain scheduled H_∞ controller allows further improvements. However, robustness with respect to model uncertainties, notably concerning the force law, remains an issue.     

An approach for the coupled simulation of machining processes using multibody system and smoothed particle hydrodynamics algorithms

The prediction accuracy of a simulation method is limited by its theoretical background. This fact can lead to disadvantages regarding the simulation quality when investigating systems of high complexity, e.g. containing components showing a fairly different behavior. To overcome this limitation, co-simulation approaches are used more and more, combining the advantages of different simulation disciplines. That is why we propose a new strategy for the dynamic simulation of cutting processes. The method couples Lagrangian particle methods, such as the smoothed particle hydrodynamics (SPH) method, and multibody system (MBS) tools using co-simulations. We demonstrate the capability of the new approach by providing simulation results of an orthogonal cutting process and comparing them with experimental data.