Meet PHOENIX INTEGRATION at the 2021 SAE WCX™ Digital Summit

April 13, 2021 - April 15, 2021
Olivier Morisot


This presentation will explore the method of performing systems level architecture trade studies using data from high fidelity CAE calculations. The method is applied to a SysML model of an IRS Rear Axle driveline with the aim of accurately predicting the lowest possible weight of the half shafts for a driveline configuration while considering complex requirements. First the parametric equations defined in the SysML model that estimate the impact torque are solved. Next a response surface model is created that takes the impact torque as an input and outputs the optimal weight of the half shaft axle. 

In order to do this, a CAE model of the half shaft axle is developed as an automated workflow. It uses a parametrized CAD model to define the geometry which is then evaluated for maximum stress and deflection with an FEA solver. The performance of all possible axle geometries is sampled using a large DOE and approximated using an RSM. An optimization workflow is then created that uses this RSM to find the optimal geometry for a specified torque load. 

This workflow is evaluated for a range of torque values and is in turn approximated using an RSM to create a single executable component that provides optimal half shaft axle weight as a function of applied torque. This axle performance component is connected to the SysML model together with a catalog of available CV Joints to enable the study of tradeoffs between weight and cost for the complete half shaft. The SysML model also integrates a requirement that checks if a chosen axle geometry can fit into a housing defined in CAD. Finally, the paper demonstrates optimization of the half shaft under complex constraints using the complete model.

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