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Dana Researchers Develop 'Virtual Prototype' Process

3 March 1999

Dana Researchers Develop 'Virtual Prototype' Process

    OTTAWA LAKE, Mich., March 3 -- The costly, time-consuming
process of producing automotive component prototypes is about to change thanks
to technology developed at Dana Corporation's Technical Research
Park located in southeastern Michigan.
    Dana calls it "virtual prototyping," a process that uses a range of
advanced computer-aided engineering (CAE) tools to generate and verify
component designs before actual hardware is produced.
    "Prior to advancements made in virtual prototyping, we used pieces of the
process that helped reduce design cycle times, but there were some
bottlenecks," said Rob Selle, manager of Dana's CAE Services.  Advancements in
CAE tools now allow us to take a component or assembly through an iterative
design cycle that simulates "real world" conditions and reduces the number of
"hard" prototypes needed before production, he said.
    The technology is available to all Dana operating divisions, Selle said.
It includes 3-D modeling, dynamic component and systems analysis, and a
multitude of Finite Element Analyses (FEA) and simulations.
    Dana's Parish Structural Division, for example, is applying the virtual
prototyping process to develop light-truck frame components and assemblies,
Selle said.  "In this case, techniques in shape and size optimization were
applied to help reduce vehicle noise, vibration, and harshness (NVH) issues.
We targeted certain vibration frequencies and modified component and assembly
stiffness to achieve a design that dampens engine and transmission vibration."
    An important part of the process is assembling a "suite of tools," such as
3-D modeling, that allow a user to accurately constrain and load components
and assemblies to produce simulated results that correlate with "real world"
data, said Selle.  "Ideally, we hope to produce one 'hard' prototype to test
and validate prior to production," he added.
    One of the world's largest independent suppliers to vehicle manufacturers
and related aftermarkets, Dana produces components and systems on more than
95 percent of the world's 700 million motor vehicles.  Founded in 1904 and
based in Toledo, Ohio, the company operates some 330 major facilities in
32 countries and employs more than 86,000 people.  Dana reported sales of
$12.5 billion in 1998.  Dana's Internet address is http://www.dana.com.