COMSOL Multiphysics for the Automotive Sector (Part 2)

In part one of this analysis, we pondered some of the potential benefits of using COMSOL Multiphysics for modeling and simulation automotive acoustics, battery design, and electromagnetic compatibility.

We emphasized the various benefits of using COMSOL Multiphysics in the research process, such as reducing the number of physical prototypes, shortening the development cycle, cost-effectiveness, time efficiency, and optimizing design accuracy, durability, and user safety.

In part two, we are focusing on the suspension system, electric motor, gearbox, and disc brakes. By using COMSOL Multiphysics, engineers can test these vehicle components under various conditions such as electromagnetic field distribution, heat generation, vibration and noise, and more.

COMSOL: A comprehensive view under various conditions

COMSOL Multiphysics allows engineers to simulate the behavior of multiple physical phenomena simultaneously, study the system’s behavior under different operating conditions, and provide a comprehensive view of the system.

Some of COMSOL Multiphysics’ key features for suspension systems modeling:

Geometry modeling: COMSOL Multiphysics is a powerful and flexible tool for creating and modifying geometries directly within the software. The CAD Import Module allows engineers to import CAD files from various sources directly into COMSOL Multiphysics without using an intermediary file format. 

Material database: COMSOL Multiphysics software and some of its add-on modules include built-in material libraries with materials and their properties. The Material Library add-on gives engineers access to 10328 materials and up to 24 separate material properties.

Optimization tools: The Optimization Module provides engineers with various tools for estimating and optimizing parameters, shape, and topology. Automotive engineers can harness it to improve the design of any devices and processes involving structural mechanics, electromagnetics, heat transfer, fluid flow, and more. 

Overall, COMSOL Multiphysics provides automotive engineers and OEMs with a cost-effective and reliable way to optimize the design of the suspension system to ensure that it meets the demanding requirements of modern vehicles.

Elevating suspension systems design

Designing a durable and efficient suspension system is a challenging task due to the complexity of the system and the various physical phenomena involved, such as mechanical deformation, fluid flow, and heat transfer. COMSOL Multiphysics provides engineers the tools to analyze and optimize system designs for  vehicle suspension. 

COMSOL Multiphysics can be used by automotive engineers for:

Optimizing suspension design: Engineers can explore different suspension configurations and materials to improve ride comfort and handling.

Predicting vehicle dynamics: By simulating various road conditions, engineers can predict how the vehicle will respond to various inputs.

Analyzing energy dissipation: Understanding how energy is dissipated during impacts can help in designing more efficient and durable suspension systems.

Developing advanced suspension systems: COMSOL Multiphysics can be used to develop innovative suspension systems, such as adaptive or semi-active systems.

Key features of COMSOL Multiphysics:

Lumped mechanical system interface: This COMSOL Multiphysics interface allows for modeling discrete mechanical systems, including masses, dampers, and springs. By setting up a simplified lumped model in the software, engineers can study the performance of the suspension system under various road conditions.

Multibody dynamics interface: This interface can be used to connect the lumped mechanical system to a 2D or 3D multibody dynamics model.

Vehicle suspension model: A model that includes three main components: wheels, seats, and the body. Each component has specific degrees of freedom (DOFs) to represent its motion.

Transient analysis: An analysis technique that allows engineers to compute the vehicle’s motion and seat vibration levels for a given road profile.

Results and insights: Through results analysis, engineers can gain insights into the vehicle’s behavior, such as roll, pitch, heave, seat displacements, and spring forces.

By leveraging the capabilities of COMSOL Multiphysics, automotive engineers can design and develop more advanced and reliable suspension systems that enhance the overall driving experience.

Learn more about COMSOL Multiphysics capabilities for suspension analysis: https://youtu.be/uXudw9bKi6c

Maximizing electric motor efficiency

In recent years, automakers have been investing in new, more advanced electric motors in order to establish a dominant edge in the market and outperform their competitors. Their success lies in the engineering optimizations of electromagnetics and electric motor design. Beyond that, a rise in demand for smaller-yet-more-powerful electric motors is increasing calls for simulation in the early stages of development, due to the complexity of the design and the risks that come with poor thermal management design. 

Comsol Multiphysics and its add-on modules provide engineers with a cost-effective and time-efficient way to optimize and test electric motors designed early in the development process. 

Some of COMSOL Multiphysics’ key features for car electric motor modeling:

Electromagnetics modeling: COMSOL Multiphysics and its AC/DCod -on  module provide an easy way to simulate electromagnetic fields. Electromagnetic interference and electromagnetic compatibility (EMI/EMC) addresses quantities like magnetic fields, current density, and induced currents. Electromagnetics engineers can use the software to examine electromagnetic effects, model in static and time-varying magnetic fields, eddy currents, and hysteresis losses, and accurately predict the performance of the motor in real-world operating scenarios.

Thermal modeling: The Heat Transfer Module provides automotive engineers with the ability to simulate accurately the thermal behavior of electric motors, including heat generation and dissipation, temperature distribution, and thermal stress under a range of operating conditions. It is built around the three modes of heat transfer: conduction, convection, and radiation. To ensure accurate modeling, the software can handle all models simultaneously, which provides engineers with the ability to solve heat transfer equations for complex geometries and boundary conditions.

Structural analysis: The Structural Mechanics Module helps users analyze the mechanical behavior of electric motors, including the forces, stresses, and deformations caused by mechanical loads.

Multiphysics couplings: COMSOL Multiphysics allows for the coupling of multiple physics modules, which enable the simulation of the interaction between electromagnetic, thermal, and mechanical phenomena in electric motors.

Engineers working on electric motor design can utilize the optimization and multiphysics capabilities of the software, as well as access the COMSOL material database to improve their designs and optimize their performance. 

With the help of COMSOL Multiphysics, engineers can identify and solve potential design problems, optimize motor performance, and ultimately create more efficient and reliable electric motors.

Streamlining gearbox performance

One of a gearbox’s basic functions is to convey power from the engine to the wheels effectively and consistently, while withstanding the dynamic forces and stresses encountered during operation. The design of the next generation gearbox must also take into account factors such as noise and vibration, as well as the growing need to minimize weight and space utilization. Therefore, engineers need to use advanced simulation tools to design and optimize the gearbox for maximum efficiency, reliability, and durability.

Some of COMSOL Multiphysics’ key features for gearbox modeling: 

Structural behavior analysis: The Structural Mechanics Module allows engineers to use finite element analysis (FEA) to predict the structural performance of the gearbox in a virtual environment including stress and deformation and find flaws in their design prototypes, therefore reducing the number of physical prototypes.

Operation, motion, and interaction simulation: The Multibody Dynamics Module can be used to simulate the motion and interaction between different components of the gearbox, such as gears and shafts.

Dynamic behavior analysis: The Rotordynamics Module is used to analyze the dynamic behavior of rotating machinery, such as the gears in a gearbox. It can predict vibration, stability, and dynamic loads.

LiveLink for MATLAB: This feature allows engineers to create custom scripts in MATLAB and integrate them into their COMSOL simulations.

Gearbox manufacturers can also benefit from COMSOL’s Optimization and Thermal Modeling tools to help in improving the gearbox’s thermal management by identifying potential sources of overheating and improving heat dissipation. Moreover, they help isolate the optimal shape or material for gearbox components with the optimization tool. 

Ensuring disc brake safety and reliability

As one of the most important control systems of an automobile, brakes simulation has become an indispensable step in the design process. There are five main safety measures that engineers consider in the testing phase of disc brakes: heat dissipation, wear resistance, stability and control, noise and vibration, and corrosion resistance. 

COMSOL Multiphysics modules can be used to provide a more detailed and accurate understanding of how the system will behave under various conditions, through: 

Chemical reaction simulation: This module is used to simulate chemical reactions that occur during the braking process, such as the decomposition of brake pad materials.

Customizable geometry and meshing: Engineers can import CAD models of the disc brake system and customize geometry and meshing to match their specific requirements.

Moreover, COMSOL Multiphysics offers benefits to disc brake manufacturers from these modules, which have been reviewed in these previous sections: Structural Mechanics Module, Heat Transfer Module, Multibody Dynamics Module, Optimization Module, and Material database. 

The design and testing of disc brakes are crucial for ensuring the safety of automobiles. Engineers use simulations to predict how the system will perform under various conditions. With the help of the COMSOL Multiphysics modules, manufacturers can optimize the disc brake system’s performance and safety while reducing costs and development time.

Conclusion for parts 1 and 2

Overall, COMSOL Multiphysics is a significant tool for automotive engineers and researchers looking to model and simulate various components of the vehicle. By using COMSOL Multiphysics, they can perform virtual experiments, gain a deeper understanding of the physical phenomena involved, and optimize designs early on in the development cycle, which saves time and reduces costs associated with physical prototyping, and reduces risks. 

Products Mentioned

All products mentioned are developed by COMSOL.

• COMSOL Multiphysics

Learn more

• Blog: COMSOL Multiphysics for the Automotive Sector (Part 1).
  Explore COMSOL Multiphysics capabilities for simulating and analyzing complex multiphysics problems, including automotive acoustics, battery design, and electromagnetic compatibility of the vehicle.
  Read more.
• Blog: Why Engineers are using Modeling and Simulation to Accelerate the Development of Electric Vehicles.
  Amidst surging consumer demand and stringent regulatory mandates, automotive manufacturers are faced with the urgent task of transitioning to the manufacture of electric vehicles (“EVs”). In this article, we explore the challenges impeding this shift and delve into how COMSOL Multiphysics aids in EV design, addressing critical concerns such as battery optimization, hydrogen-based technology, acoustic performance, and fluid dynamics.
  Read more.