Static Loading Analysis of Third Row Floor Duct System Using Finite Element Method 2017-01-0168

In current scenario, there is an increasing need to have faster product development and achieve the optimum design quickly. In an automobile air conditioning system, the main function of HVAC third row floor duct is to get the sufficient airflow from the rear heating ventilating and air-conditioning (HVAC) system and to provide the sufficient airflow within the leg locations of passenger. Apart from airflow and temperature, fatigue strength of the duct is one of the important factors that need to be considered while designing and optimizing the duct. The challenging task is to package the duct below the carpet within the constrained space and the duct should withstand the load applied by the passenger leg and the luggage. Finite element analysis (FEA) has been used extensively to validate the stress and deformation of the duct under different loading conditions applied over the duct system. In this paper, the focus is to predict the stress level and deformation or displacement of third row floor duct design to withstand the maximum loading conditions. The input for the analysis is the force acting on the duct at different locations maintaining at the room temperature. The result predicted is the stress distribution throughout the duct and displacement at load acting locations. Prototype parts were made for the floor duct design and loading test was carried out in the test bench to know whether the deformation is happening or not when the load is applied over the duct at different locations. There is no failure or breakage observed in simulation and bench test with the proposed material of the duct and grills. Successful validation of the simulation process has led to the application of this methodology in the pre-production stage of new programs during the design phase. This simulation methodology helps in finding out stress and displacement results of the duct in the design stage of the program and aids in reducing the physical testing iterations.