Numerical Simulation/Analysis and Computer Aided Engineering for Virtual Protyping of Heavy Ground Vehicle

Abstract

This doctoral project dissertation deals with the investigation of simulation/analysis in the product development process of specialized heavy ground vehicle engineering which posts some of the most challenging engineering problems. The focus of the project is to keep the process of simulation efficient by structuring and managing of models and the method, for usage early in product development cycle. Previous work in this area has focused on developing faster calculation algorithms, more specialized simulation software, and elegance. For simulation/analysis, in today's competitive engineering environment in which engineers strive to develop designs with high performance, and reduced time and cost, there is also a growing demand to capture reality more accurately and efficiently when numerically modeling a problem in Computer Aided Engineering (CAE). Accurate simulation coupled with educated simplifications and other modeling techniques, allow for the concept of Virtual Prototyping (VP), upfront and in design-integrated manner for the product development which would reduce much of the status quo Specialized or Traditional CAE, and Physical Prototyping or Test, to ensure a problem free product launch, overall cost and time savings in the design work - essentially resulting in lean, economical and accelerated product development. In line with increasingly popular new product development and project management paradigm, and also as trade studies, in this doctoral project design works are performed and managed, investigated on, and `up or front loaded' using various contemporary CAE simulation software packages to Virtually Prototype and verify industrial design and wide variety of real world problems commonly came across in the design of Specialized Road and Rail Heavy Ground Vehicles. The numerical simulation technology capabilities are fully explored to specifically tackle the kinematics, dynamics, statics, and structural problems, some with the added realism of today's 3D high fidelity graphical environment of VP. Adopting various modeling and VP strategies, the work for the doctoral project is performed with increasing complexity and some coupled with testing to compliment or validate simulation/analysis result as a show of accuracy providing high level of confidence in further design customization, synthesis, and iterations. The main purpose of the doctoral project is to arrive at a `Virtual Prototyping driven' rather than a `Virtual Prototyping verified' design, although much verification is performed to confirm acceptable virtual prototype fidelity.