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A methodology is presented for developing two tools for design guidance of joints in car bodies. The first tool rapidly predicts the performance characteristics of a given joint. The second finds a joint design that meets given performance targets and satisfies packaging and manufacturing constraints. These tools translate the design parameters defining the geometry of a joint into performance characteristics of that joint and vice-versa. The methodology is demonstrated on a joint of an actual car.

Ford Motor Company has developed a Computer Aided Engineering (CAE) process for predicting NVH performance of its forward model vehicles. This process utilizes simplified models to drive the upstream design effort before detailed drawings are available and then verifies the design with detailed models. The process can be used to determine and evaluate the most effective design modifications and to assist in resolving downstream problems after prototype vehicle evaluations. This paper outlines this process and also gives examples from the work which was done to support the new 1992 Econoline design.

Finite element simulations of powertrain assemblies and components such as an engine block, transmission case, and structural oil pan, are regularly carried out at Ford Motor Company to provide directions for design improvements relevant to durability, minimum weight, noise and vibration characteristics. This paper presents hands-on experience with analyses of two powertrains in terms of computational strategies and resource requirements. The course of future analysis work in the light of current developments in computer technology, is also presented.

The purpose of this study was to analytically predict the dynamic behavior of a powertrain assembly and provide directions for structural design improvements relevant to durability, optimum weight, NVH characteristics, etc. To achieve this objective, a finite element model of the powertrain assembly was constructed and normal mode analysis was performed with the MSC/NASTRAN finite element computer program. Natural frequencies, mode shapes and modal strain energy densities were computed. Results were post-processed with the MOVIE — BYU color graphics package. An accurate, easy to interpret, presentation of the dynamic results was achieved with color-coded strain energy density animations of the first two eigen-solutions.