Simulation and Testing of Products (FSI-HSI)

Academic year 2024/2025
Supervisor: František Samek  
Supervising institute: ÚST all courses guaranted by this institute
Teaching language: Czech
Course type: departmental course
Aims of the course unit:

The course provides the students a practical knowledge about the phase of product certification for automotive industry. The graduate should be able to select effectively the required tools of CAE simulation and physical testing when validating of a proposal to shorten the development cycle and preventing problems in using the product by customer. The related area of product validation is prototyping while taking into account the current technological possibilities including the specifics of thick-walled optical polycarbonates and other reflective systems and solving the specific examples of prototyping. The practical examples demonstrate the suitability of the used prototype technology for obtaining the desired properties of individual parts of the headlights. The follow-up area is using of tolerance analyses and simulations to verify or to optimize the dimensions of individual components and sub-assemblies in the development stage of headlights, including verification of products while using 3D scanning systems GOM (one of the most advanced optical systems in automotive industry).
Students are trained in practical knowledge of the application of CAE simulations, prototyping with technology of prototype optical elements (additive technology, vacuum casting, plastic moulding, precision CNC machining), with following surface treatment according to contemporary standards, technology of 3D scanning of components and re-use of scanned data for a product validation.
Learning outcomes and competences:
 
Prerequisites:

A basic knowledge of polymers and their mechanical properties, CAD and CAE technologies. Technological characteristics of the machining methods.
Course contents:

The course is focused on the field of the product design verification made with computer simulations and physical testing of the product samples. The most commonly used types of simulations and tests (vibrations, thermal management, kinematics, manufacturing technology, lighting characteristics, electronics) will be presented in detail with using of tolerance analyses and simulations in the headlight development (tolerance types and tolerance chains for optical elements and plastic materials), calculation methods of tolerances and their specific applications in tolerance analyses and simulations. The follow-up area is prototyping, where the students learn to involve the prototype workshop into a real process of development headlight and back group lamps in the automotive industry, including the production of prototype optical members. Students will become familiar with the used prototype technologies of individual component and the subsequent surface finish. The samples of components are by optical scanning systems included retroactively into the analyses and related validation of parts.
Teaching methods and criteria:
 
Assesment methods and criteria linked to learning outcomes:

Completion of the course: graded credit
Student requirements: attendance + seminar work elaborated individually or in a team (according to the number of registered students)

All of exercise lesson are obligatory. The student’s own work and knowledge is assessed in practicals. According to the studied topic some lessons will be practicals - carried out in the lab, and some will be focused on the theory - calculations carried out in the classroom in a seminar form. Absence from seminars should be substituted for by attending a seminar with another study group or individually by the agreement with the teacher. Lessons may be occasionally inspected by the head of the department.
Controlled participation in lessons:
 
Type of course unit:
    Lecture  12 × 2 hrs. optionally                  
    Laboratory exercise  1 × 2 hrs. compulsory                  
Course curriculum:
    Lecture

1. The simulation in the development process - introduction
2. Simulation of thermal and mechanical loading of headlights
3. Simulation of kinematics and manufacturing technology of components mad by from polymers by injection process
4. Measurements of temperature on prototypes
5. Practical solutions to the problems caused by overheating in the headlight
6. Chemical tests on headlights
7. Overview of prototype technologies used in developing of headlight
8. Specific requirements for the prototype model of back group lamp
9. Rapid prototyping technology and non-contact measurement of LED modules
10. Specific requirements for 3D model for prototyping
11. Optical measuring systems in the automotive industry – Tritop
12. Optical measuring systems in the automotive industry – Atos
    Laboratory exercise

13. The structure of prototype workshops and testing rooms in practice (excursions)
Literature - fundamental:
9. HUTTON David.V. Fundamental of finite element analysis. The McGraw−Hill Companies, 2004 .
Literature - recommended:
1. KOLOUCH Jan. Strojírenské výrobky z plastů vyráběné vstřikováním. Praha: SNTL, 1986.
2. ZEMAN Lubomír. Vstřikování plastů. Praha: BEN, 2009. ISBN 978-80-7300-250-3.
3. GORDON N. Ellison. Thermal Computation for Electronics: Conductive, Radiative, and Convective Air Cooling. CRC Press, 2011. ISBN 978-1-4398-5017-6.
4. MEYWERK Martin. CAE-Methoden in der Fahrzeugtechnik. Springer, 2007. ISBN 978-3-540-49866-7.
5. FASTERMANN Petra. 3D – Drucken: Wie die generative Fertigungstechnik funktioniert. Springer, 2014. ISBN 978-3-642-40963-9.
6. TRES Paul A. Designing Plastic Parts for Assembly. Hanser, 2014, ISBN 978-1-56990-555-5.
7. KENNEDY Peter K., ZHENG Rong. Flow Analysis of Injection Molds. Hanser , 2013. ISBN 978-1-56990-512-8.
8. EZRIN Myer. Plastics Failure Guide: Cause and Prevention. Hanser, 2013. ISBN 978-1-56990-449-7.
9. HUTTON David.V. Fundamental of finite element analysis. The McGraw−Hill Companies, 2004
10. GRIEB Philipp. Digital Prototyping . Hanser, 2010. ISBN 978-3-446-42318-3.
The study programmes with the given course:
Programme Study form Branch Spec. Final classification   Course-unit credits     Obligation     Level     Year     Semester  
N-STG-P full-time study MTS Modern Technologies of Lighting Systems -- GCr 4 Compulsory 2 1 S
C-AKR-P full-time study CLS -- GCr 4 Elective 1 1 S