EnginSoft - Conference Abstracts

EnginSoft Users' Meeting 2006
Le Tecnologie CAE nell'Industria

Structural Non-linear Analysis of a Steel/Aluminum Cover for Hydraulic Actuated Gearbox in ANSYS Structural Environment

Brazzi Alessandro - Magneti Marelli Powertrain

Abstract

Automated-manual gearbox are increasing their presence on automotive market during last few years: in this scenario, Magneti Marelli Powertrain S.p.A. designs, tests and realizes an electro-hydraulic version, which is mostly known with the brand name “SeleSpeed”®.

During design phases, various parts of the mechanical component are numerically simulated to grant their survival, good performance and safety by means of FEM, CFD and 1D codes.

Mainly for safety reasons, one of the most important part to study is the so-called brake cover, which is a small cover internally stressed by a pressure that can raise up to hundreds bars.

In the analyzed version, it is made by two parts, a flange in stainless steel and a cover in aluminium, which are kept together by means of 4 screws.

Performed analysis had the following key features:

1. Full use of surface to surface contact elements to simulate the real contact between various sub-parts
   
2. Non linear flange material, to take into account plastic deformations
   
3. Pre-stress on screw due to initial phase of their tightening.
   

Analysis results have been then compared to test bed results, to ensure that the applied way of calculations would be adequate.

In a further activity, ANSYS model has been used coupled with modeFRONTIER to optimize various geometry and mounting parameters.