Design and Development in Automotive and Mechanical Engineering (M. Eng.)

Numerical Methods in CAE

Learning Outcomes and Competences

Once the module has been successfully completed, the students can …

Knowledge and Understanding

• Understand the basics of mathematical concepts within the framework of the topics in section 4
• Have advanced knowledge of engineering mathematics and numerical methods in particular
• Understand the relevance of mathematics for mechanical engineering

Use, Application and Generation of Knowledge

• Apply mathematical concepts within the framework of the topics in section 4
• Decide whether a solution is plausible or not
• Analyse advanced problems of mechanical engineering and work out mathematical solutions

Communication and Cooperation

• Make use of the knowledge, abilities and competences in order to evaluate a given application problem
• Communicate within a team to work out a solution to a given problem

Scientific Self-Conception/ Professionalism

•  Justify a solution methodically
• Assess their abilities in comparison to their fellow students

Contents

• Advanced topics of matrix calculus
• Analysis of functions of several variables (especially optimisation)
• Iterative methods for solving linear equation systems
• Power series, Taylor series, Fourier series
• Nonlinear equations and nonlinear equation systems
• Numerical methods for initial value problems of ordinary differential equations

Examination Forms and Prerequisites for Awarding ECTS Points
Written examination (90 mins); graded

Design and Development 1

Learning Outcomes and Competence

Once the module has been successfully completed, the students can...

Knowledge and Understanding

• Understand and explain the concepts and principles of ecologic and economic design.
• Describe the product development process.
• Understand the basics of reliability engineering.

Use, Application and Generation of Knowledge

• Apply the concepts and principles of ecologic and economic design in their own projects and processes.
• Take different perspectives and points of view on a given situation, weigh them up against each other and choose the best design or process with respect to ecologic and economic aspects.
• Use the methods and concepts of reliability engineering.
• Calculate reliability characteristics.
• Familiarize themselves with new ideas and topics based on their basic knowledge in reliability. Scientific Innovation
• Improve the design of engineering concepts and processes in order to improve their ecologic and economic aspects and their reliability.
• Communication and Cooperation
• Communicate actively within an organization and obtain information about ecologic and economic design Aspects.
• Communicate and cooperate within the group in order to find adequate solutions for ecologic and economic design aspects and their reliability (e.g. FMEA). Interpret the results of the reliability assessments and draw admissible conclusions.
• Use the learned knowledge, skills and competences to evaluate the reliability and interpret the results according to other aspects. Present reliability contents and discuss them.

Scientific Self-Conception/ Professionalism

• Derive recommendations for decisions from a ecologic and economic perspective on the basis of the analyses and evaluations made.
• Justify the results of reliability analysis theoretically and methodically.

Contents

a) Design Methodology Case Study: Design constraints, QCD requirements, design and development Team, breakdown structures, functional decomposition of technical systems, product design specification, V – Cycle, tender and project cost management, change and configuration Management, safety management and engineering

b) Ecologic and Economic Design: Resources, future resource availability, negative effects of industrial processes and products on humans and the environment, environmental burden of disease in Europe, EU directives on environmental protection (design engineering view), ECO-design methods including Luttrop's "Golden Rules and additions", ecological design and economic design - no area of conflict!

c) Reliability: Definition, significance and overview of reliability, techniques in the product development and in the product life cycle; statistics, probability theory, life time distribution, reliability of systems; FMEA, fault tree analysis (FTA), Markoff theory, Boolean system theory; proof of reliability, planning of tests, collecting field data; reliability software

Examination Forms and Prerequisites for Awarding ECTS Points

Design Methodology Case Study: Certificate
Ecologic and Economic Design: Written exam 90 minutes (closed)
Reliability: Written exam 60 minutes (open)

Advanced Strength of Materials

Learning Outcomes and Competences

Once the module has been successfully completed, the students can …

Knowledge and Understanding

• Understand the sequence of a linear finite element analysis.
• Understand in depth the concept of nodes, integration points and interpolation functions.
• Understand the influence of various factors on the lightweight potential of a structure.

Use, Application and Generation of Knowledge

Use and Transfer

• Apply the finite element method to analyse the deformation and stress/strain state of a structure.
• Apply lightweight design concepts in relation to materials and shapes.
• Analyse the failure behaviour of technical sandwich structures.

Scientific Innovation

• Optimize sandwich structures for minimum weight under different side conditions.
• Improve the weight-to-load ratio of structures.

Communication and Cooperation

• Interpret the results of a numerical simulation and a lightweight optimization and draw admissible conclusions.
• Present technical contents and discuss them.
• Communicate and cooperate within the group in order to find adequate solutions for the task at hand.

Scientific Self-Conception/ Professionalism

• Justify solutions theoretically and methodically.
• Reflect and assess the abilities of group members.

Contents

a) Lightweight Design: Principles and objectives of lightweight design; One-dimensional members (Bars and Beams); Plates and shells; Stability problems; Selected examples of lightweight design

b) Advanced Finite Element Method: Theoretical background of FEM, fundamental equations, numerical accuracy and convergence, applications and influence of boundary conditions, nonlinearity (material); lab exercises

Examination Forms and Prerequisites for Awarding ECTS Points

Advanced Strength of Materials: Written exam, 120 minutes, graded
Advanced Finite Element Method: Individual semester project, not graded

Vibration and Acoustics 1

Learning Outcomes and Competences

Once the module has been successfully completed, the students can...

Knowledge and Understanding

• Explain the basic procedure of vibrations and acoustic measurement techniques and understand the connections within theoretical basics and practical measurement.
• Describe basics of mechanical vibrations, optical, holographic and other vibrational measurement techniques.
• Basic knowledge in the mathematical, mechanical and optical fundamentals of vibrational measurement techniques.
• Recognize the significance of the subject to development process of mechanical and automotive systems.
• Understand and explain single degree of freedom (SDOF) vibrational models, digital signal processing (DSP) and fourier transform process (DFT and FFT), basics of laser light and holography.

Use, Application and Generation of Knowledge

Use and Transfer

• Apply principles of optical laws, DSP, DFT and FFT to Frequency Response Function (FRF) and Order Tracking measurements.
• Create lab reports and presentations.
• Analyse vibrational and acoustic behaviour of chosen automotive components.
• Recognize and classify connections.
• Analyse vibrational and acoustic problems and derive or develop solutions.
• Take different perspectives and points of view on a given situation, weigh them up against each other and make an assessment.
• Design components with wanted vibrational and/or acoustic properties.
• Calculate basic properties of SDOF models.
• Familiarize themselves with new ideas and topics based on their basic knowledge.

Scientific Innovation

• Develop concepts for the vibrational and acoustic optimization of mechanical and automotive components.

Communication and Cooperation

• Interpret the results of vibrational and acoustic measurements and draw admissible conclusions.
• Present FRF and operational deflection shapes and discuss them.
• Communicate and cooperate within the group in order to find adequate solutions for the task at hand.

Scientific Self-Conception/ Professionalism

•  Justify the solution theoretically and methodically.
•  Reflect and assess one's own abilities in a group comparison.

Contents

a) Vibration and Acoustics Measurement: Vibration measurement by mechanical means, optical and laser basics, vibration measurement by interferometric and holographic means, acoustic noise measurement, analysis of dynamic signals.

b) Laboratory Vibration and Acoustics Measurement: Introduction and handling of measurement equipment, FRF measurement on an automotive component, order tracking measurement on a car, Speckle interferometry, laser vibrometry.

Examination Forms and Prerequisites for Awarding ECTS Points

Written exam, 90 minutes, graded
Lab reports and tests, not graded

Integrity of Structures

Learning Outcomes and Competences

Once the module has been successfully completed, the students can...

Knowledge and Understanding

• Understand the advanced methods to evaluate the operational safety and integrity of engineering/car structures under static and cyclic loading
• Understand and explain the procedure for a life-time-assessment of components under variable amplitude loading.
• Basic knowledge about fatigue behaviour under complex multiaxial loading
• Understand principles and methodology of failure investigation
• Explain typical failure patterns and failure modes of engineering structures
• Understand reasons, characteristics and types of failures.

Use, Application and Generation of Knowledge
Use and Transfer

• Apply the concepts for an experimental and theoretical life-time-assessment for cyclically loaded components to reallife problems
• Apply fracture mechanics to cracked structures under quasistatic and cyclic loading
• Calculate the life time until fatigue failure by hand for simple applications and load-time-histories
• Calculate the life time until fatigue failure using commercial software programs
• Analyse failed specimen in terms of failure cause and give technical solutions for remedies
• Create solutions how to prevent failures

Scientific Innovation

• Improve the design of engineering structures in order to improve their safety and reliability.

Communication and Cooperation

• Interpret the results of the component safety and lifetime and draw admissible conclusions.
• Use the learned knowledge, skills and competences to evaluate the safety and integrity of engineering components and structures.
• Communicate and cooperate within the group in order to find adequate solutions for the task at hand.

Scientific Self-Conception/ Professionalism

• Derive recommendations for decisions concerning the safety of components under service loading and their release on the basis of the analyses and evaluations learnt.

Contents

a) Integrity of Structures: Advanced concepts for the life time assessment under variable amplitude loading: Nominal stress concept for cyclic loading, Structural stress concept for cyclic loading, local stress concept for cyclic loading, local strain concept for cyclic loading, fracture mechanics concept Application of numerical tools for the life time prediction Selected topics / ongoing research topics: e.g. very high cycle fatigue (VHCF); fatigue behaviour of composite materials; Influence of edge conditions on fatigue behaviour, multiaxial fatigue… Laboratory exercises: Non-destructive testing, experimental determination of material and component flow curve, Neuber`sLaw, Masing  behaviour, local stress-strain loops, test drives with strain gauges, collecting data for load time history, numerical life time assessment

b) Failure Analysis: Historical failures, typical failures at car structures, reason for failures, concepts for component optimization, definition and classification of failures, methods of failure analysis, characteristics of failures under static and cyclic mechanical, thermal and chemical loading, practical case studies and exercises

Examination Forms and Prerequisites for Awarding ECTS Points

Written exam, 120 minutes, graded
Lab reports and lab tests, not graded

Dynamics

Contents

a) Multi Body Systems: Description of finite rotations, rotation matrix, speed and acceleration, forces and constraints, equations of motion, state-space equations, numerical solutions, user defined force elements.

b) Simulation of Multi Body Systems: Introduction to Matlab Symbolic toolbox and Simcape. Modelling and Simulation of different examples with SimMechanics, e.g.: mechanical conveyor, hydraulic excavator, Modelling and calibration of subsystems of “Esslingen Driving Simulator” and system integration in group work.

Examination Forms and Prerequisites for Awarding ECTS Points

Multi Body Systems: Written exam, 90 minutes, graded
Simulation of Multi Body Systems: Group projects with presentations, not graded

Design for Manufacturing

Contents

a) Production-oriented Product Design: Part 1: Root cause investigation: root cause investigation on failing products with the aim to identify failures in production oriented product design, 4 to 6 cases, ambivalent data situation, insufficient information, without obviously correct answers and a ticking clock, which requires fast actions, inter-cultural investigation teams.

Part 2: Basics (process, weldability of materials and design) for relevant joining technologies (e.g. laser beam welding, resistance welding, friction welding, ultrasonic welding, mechanical joining, adhesive bonding), methods of quality assurance in production, health and safety instruction, industrial applications, practical laboratory

Part 3: Textile techniques, composite design, thermoplastic and thermoset processes, organic sheet moulding, taping, resin transfer moulding, reactive injection moulding, repairing of composite materials, joining

b) Product Life Cycle Management: Understanding the method LCA Life Cycle Assessment, trends in industry and society, training and application LCA software GaBi; executing an LCA in teams; Analysing industrial LCAs

Examination Forms and Prerequisites for Awarding ECTS Points

Written exam, 120 minutes, graded
Product Life Cycle Management: Individual semester project

Advanced Materials Technology

Contents

a) Advanced Engineering Materials: Metals: Car body materials, high strength steel sheets, multiphase steels, press-hardening steels, high strength aluminium sheets, tailored part properties, integrated approach, recent developments Case Studies: Crash Management systems in automotive; lightweight materials and material selection criteria’s; high strength aluminium; materials parameters; international standards for crash management; manufacturing methods like forming and joining; design of crash management systems; repair

b) Surface Technology: Basics in corrosion, thermal coating, CVD, PVD, electrochemical deposition, corrosion protection of stainless steel and light metals, leak, sealing, dip coating, design of the corrosion protection for all the components of passenger cars, testing methods

c) Composites: Understanding polymers, classification, thermal and mechanical properties, reinforced polymers, fibres, laminate properties, testing composite materials, designing with polymers and reinforced materials

Examination Forms and Prerequisites for Awarding ECTS Points

Written exam, 120 minutes, graded

Design and Development 2

Contents

a) Advanced CAD: General introduction in the latest Revision CREO from PTC with practices; Learning of special advanced features of a CAD system; Learning of special advanced modules of a CAD system, like sheet metal, surface, mechanism, cabling and piping. Several programing tools and possibilities; Criteria for choosing a CAD System; Subassembly and skeleton technology; CAD and Internet; Data exchange, direct and indirect data exchange; Many practice by using the CAD-System by working out examples; Theoretical background of CAD-System modules.

b) Design of Experiments: General introduction into DOE, differences to experience-based test planning, execution and results of a DOE; Attempts plan: selection parameters to be investigated and result sizes, establishing the testing area; Test plan designs: Overview DOE designs (factorial, response surface, mixture, optimal designs), selection of designs; Creating designs with a DOE software tool; Specific variables in the DOE: randomization, blocks replication, resolution / confounding; Evaluation of experimental design results: effects and effect size, interactions, statistical tests in the DOE, review the validity; Optimization calculation, prediction and confirmation tests: graphical representation of the effects of parameters, numerical optimization, predict outcomes, evaluation of test results; Application of the DOE to some practical examples as well to a final exercise with all the main points mentioned

Examination Forms and Prerequisites for Awarding ECTS Points

Advanced CAD: Written exam 60 minutes, graded, + Several attestations, not graded
Design of Experiments: Written exam 60 min, graded

Vibration and Acoustics 2

Contents

a) Vibrations: Introduction to the basic theory of vibrations; practical application to typical structural noise and shake problems; principles of Fourier analysis and order tracking; multiple degree of freedom systems.

b) NVH In Automotive Systems: Definition of NVH; acoustic and vibration problems in vehicle systems.

c) Computer-Aided Vibration Analysis: Simulation of practical vibration problems (CAT).

Examination Forms and Prerequisites for Awarding ECTS Points

Written exam, 90 minutes, graded
Laboratory reports and tests, not graded

Project Work

Contents

a) Project Work: Application of project management, constitution of hierarchy (project-manager, teams members), constitution of project structure (time schedule, work packages), realisation of given tasks, documentation and evaluation of results

b) Project Work – Presentation: Presentation of results within a seminar, project feedback

Examination Forms and Prerequisites for Awarding ECTS Points

a) Group report
b) Presentation in a group (20 min.) + discussion (10 min.)

Master Thesis

Contents

a) Soft Skills: Communication: Sender/receiver model, levels of communication, perception and interpretation, NLP Presentation: Generation of presentations, advanced presentation techniques Teambuilding: Individual types according to MBTI, Team Set-Up Management and Leadership: Aims, Missions, Visions, Values, Corporate Governance, Motivation, Leadership Competence

b) Master Thesis: Constitution of project structure (time schedule, work packages), realisation of given task with scientific methods and within a given timeframe, documentation and evaluation of results

c) Defence: Presentation and defence of results

Examination Forms and Prerequisites for Awarding ECTS Points

a) Group work with test, oral presentation 30 minutes
b) Thesis report
c) Presentation and oral examination , 30 minutes