Slide Animations
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Abstract
This paper introduces an innovative approach in the field of Computer-Aided Engineering (CAE) for enhancing the safety and efficiency of heavy construction and off-highway vehicles. The primary focus is on improving Roll-Over Protective Structures (ROPS) and Falling Object Protective Structures (FOPS) through advanced simulation techniques. The traditional method of ensuring the integrity of these safety features heavily relies on physical destructive testing, governed by ANSI/ITSDF B56.6 standards. However, this research proposes a novel use of the Abaqus CAE platform to simulate multi-impact scenarios using a dynamic implicit solver, which offers a more time-efficient alternative to the Abaqus explicit method, particularly for simulating ten consecutive impacts of a cube.
The study details a simulation protocol where a 45kg test cube is dropped ten times from a height of 1500 mm onto the protective structures, aligning with the standard's requirements. The goal is to limit permanent deformation to less than 18 mm without structural fractures, as mandated in ANSI/ITSDF B56.6-2011, section 8.16.3. The research provides a comprehensive comparison between the simulated results and those obtained from traditional testing methods, demonstrating a high correlation in terms of permanent deformation outcomes.
The findings highlight the potential for significant reductions in cost and time during the product development cycle. They also confirm the reliability of CAE tools in predicting the structural integrity of ROPS and FOPS under real-world impact conditions. This paper suggests a paradigm shift in the methodology of heavy machinery safety testing, promoting more efficient and equally reliable alternatives to physical destructive testing.
Presenter Bio - Arshad Khan
Arshad is a seasoned Mechanical Engineer with a master’s degree in Mechanical Engineering (CAD/CAM) from Motilal Nehru National Institute of Technology (MNNIT), Allahabad. Specializing in Computer Aided Design and Finite Element Method, Arshad currently excels as a Virtual Analysis Specialist at CNH Industrial, a role he has held for two years. Arshad has 20 years of experience encompass design analysis, validation in the automotive and construction sectors, and expertise in a wide array of simulations and fatigue analyses.
Arshad’s technical acumen in dynamic, frequency response, and various fatigue analyses is complemented by his contributions to virtual shake table simulations and Test-FEA correlations. His analytical prowess extends to investigating field failures and implementing cost-reduction strategies, showcasing his ability to blend technical expertise with strategic problem-solving.
An active participant in the engineering community, Arshad’s insights are shared in his published work at the Abaqus India Regional User’s Meet. His paper, "Random vibration analysis and fatigue life evaluation of auxiliary heater bracket," underscores his commitment to advancing his field.
At CNH Industrial, Arshad is not just a specialist; he is a mentor and leader, driving innovation and setting standards in FEA methodologies and support for testing requirements. His career reflects a dedication to excellence in mechanical engineering, making him an invaluable asset to his industry.
