Motorcoach Driver Fatigue Study Sponsored by the F ederal Motor Carrier Safety Administration
FEMFAT =Fatigue Analysis by Finite Element Method; · PDF fileMulti Axial Fatigue Analysis F...
Transcript of FEMFAT =Fatigue Analysis by Finite Element Method; · PDF fileMulti Axial Fatigue Analysis F...
![Page 1: FEMFAT =Fatigue Analysis by Finite Element Method; · PDF fileMulti Axial Fatigue Analysis F ylhfr F zlhfr F xlhfr F yrhfr F zrhfr F xrhfr F yrhre F zrhre F ylhre F zlhre linear stiffness](https://reader033.fdocuments.in/reader033/viewer/2022051719/5a731af87f8b9aa2538e59a6/html5/thumbnails/1.jpg)
FEMFAT =Fatigue Analysis by Finite
Element Method; stress based
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STRUCTURAL
ANALYSIS
DEPARTMENT
Strength / Durability(16 engineers)
Dynamics / Acoustics(10 engineers)
STRUCTURAL ANALYSIS Department
Software Development(10 engineers)
Software Sales(3+4 engineers)
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ECS Software Products
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Finite Element / Multi Body Simulation
& Fatigue Analysis
Fatigue Test Lab
Engine Test Lab
Drivetrain Test Lab
Test Track
Synergy Analysis / Testing
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Multiaxial Fatigue Live Prediction using MBS
Supported
by MBS
Full vehicle simulation Test bench (components)
Loads, load spectra:
- Multi-axial loading (non-proportional load-/time data)
- FLP with modal stresses
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Double lane change
Lateral acc. CabSpeed 60 km/h
Roll angle CabSpeed 60 km/h
Lateral Dynamics (double lane change)
Comparison Rigid/Independent Axle
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MBS / FEA + Fatigue Simulation Vehicle Body
Basic FE-MeshLocal remeshing
of spot-joints
Fatigue prediction
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Multi Axial Fatigue Analysis
Fylhfr
Fzlhfr
Fxlhfr
Fyrhfr
Fzrhfr
Fxrhfr
Fyrhre
Fzrhre Fylhre
Fzlhre
linear
stiffness effects
load time series for
various maneuvers• gravel road
• body twist
• cobble stones
• belgian block
• chuck holes
• figure 0
• figure 8
Unit load cases for
cab suspension forces
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Simulation: crack initiation at 6 h
Test:
crack detected
after 48 h
Truck Cab Durability Analysis
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Test:
crack detected
after 192 hSimulation: crack initiation at 50 h
Truck Cab Durability Analysis
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Test: 12 hSimulation: 1 h
... Contact
affected
area
Truck Cab Durability Analysis
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Detailed Result Output for SPOT Nodes in
VISUALIZER
12
Force based SPOT assessment
Stress based SPOT assessment
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Result: damage distribution
MAT 203
MAT 205
Welding modeling
guideline
Chassis Frame, Weldings
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Opening in the IHV- tube
5,730,27
0,41
1,86
Comparison FLP - Test bench
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Joints of IHV- tubes
29,1
Comparison FLP - Test bench
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POWERTRAIN Simulation
Engine/Gearbox Analysis
Durability
Optimization
Acoustics
Cranktrain Dynamics
Geartrain Dynamics
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Influences from Production in FEMFAT
Production Processes
Metal Forming
Sand-/ Permanent
Mold CastingDie Casting
Casting
Injection moldingMore to come...
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Seed
Mold Wall
Secondary DAS
Grain Size
Influence on the Fatigue Limit
SDAS
Tsolid Tcool
.
Fati
gu
e L
imit
Fac
tor
Typical ranges
Sand-/ Permanent Mold Casting
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Correlation with test results
Nominal material
propertiesBoundary layer
model
Test result
Influence from Die Casting on Fatigue Life
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Improved Method for the Assessment of Short
Fiber Reinforced Plastics
0,00 0,25 0,50 0,75 1,00
0,2
0,4
0,6
0,8
1
NP
4mm
längs
KP
2mm
quer
KP
2mm
längsKP
4mm
längs
aXX
+aYY
+aZZ
=1
KP
4mm
quer
N=107
N=106
N=105
PA 6T/6I-GF40+MX25
konditioniert
R=0,1
f=10 Hz
23 °C
Kt=1,0
no
rmie
rte
Ne
nn
sp
an
nu
ng
sa
mp
litu
de
S
a,n
orm
(lo
g.)
[N
/mm
²]
mittlere Faserorientierung in Fließrichtung aXX
[%]
aZZ
~ 0
NP: Normprüfkörper
KP: Kurzprüfkörper
No
rma
lize
d lo
ga
rith
mic
str
ess a
mp
litu
de
Fiber orientation
Conditioned
R=0,1
F=10 Hz
23 C
Kt=1,0
NP: Standard specimen
KP: Short specimen
longitudinal
longitudinal
longitudinal
laterallateral
20
Influence Factors:
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Assessment of Load Factors at a Given Point in
Time as Car Chart in VISUALIZER
• Put all nodes of interest
in DETAILED
RESULTS group
• Start FEMFAT analysis
• Start VISUALIZER
• Select a node
• Display stress history
• Select a point
• Display load factors
• Load factors are sorted
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Accelerated visualization of detailed weld geometry in
VISUALIZER
22
Example: Rear axle with 61 welding seams
Visualization of detailed weld geometry of all
welding seams:
Only 7 frames per second !
Visualization of detailed weld geometry of
active welding seam only:
Now 38 frames per second !
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FEMFAT User‘s Worldwide – Commercial
EUROPEAUDI MUL
AVL List MUL
BMW MUL
BMW Motoren MUL
BOMBARDIER Transportation MUL
DAIMLER MUL
FEDERAL MOGUL MUL
FORD Motor Company MUL
FORD Werke MUL
IVECO MUL
Kolbenschmidt AG MUL
MAN Nutzfahrzeuge MUL
MAN Diesel SE MUL
MTU Friedrichshafen MUL
PORSCHE MUL
ROBERT BOSCH MUL
SCANIA MUL
SKODA Auto MUL
VOLKSWAGEN MUL
WINERGY / Flender MUL
ALSTOM
ALTAIR Engineering
BEHR GmbH & Co KG
CAE Engineering
CONTINENTAL Automotive
COSMA Engineering
DELPHI Diesel Systems Ltd.
DEUTZ AG
Doppelmayr Cable Car
Engelke Engineering Art GmbH
EvoBus GmbH
FESTO GmbH
FEV Motorentechnik Aachen
FIAT POWERTRAIN CRF
FKA Aachen
GEISLINGER
GE JENBACHER Energiesysteme
Georg Fischer Automotive
HILTI Entwicklungsges. mbH
AMERICAAVL List MUL
FORD Motor Company MUL
Karl Schmidt Unisia MUL
MPT TTG Toronto MUL
TOYOTA R&D Center MUL
CAE Lynx
CHRYSLER
Continental Automotive
DETROIT DIESEL
FEV Engine Technology, Enc.
Joe Gibbs Racing Inc
Neumayr Tekfor
NISSAN Technical Center
SIFCO
VW do Brasil Trucks
THYSSEN KRUPP
ASIADAIHATSU Motors MUL
DOOSAN INFRACORE CO.Ltd. MUL
HINO Motors MUL
HONDA R&D MUL
HYUNDAI Motors MUL
MAHINDRA & MAHINDRA MUL
MITSUBISHI Motors MUL
MITSUBISHI FUSO MUL
NISSAN Motors MUL
SUZUKI Motors MUL
TOYOTA Motors MUL
AKADEMI CADCAM Sdn. Bhd.
CHERY Automobile
Chongqing Hongyan ChangLi
DOOSAN Engine
MBtech India
DONG YANG Piston Co. Ltd.
VE Commercial Vehicles Ltd.
FAW First Automotive Works
Finite to Infinite
F-Tech Co Ltd.
GARGASO Engineering Co. Ltd
HHI Maritime
ILJIN Global Co. Ltd
IRAN KHODRO Powertrain
ISUZU Motors
JATCO Korea Engineering Corp.
KATech
KAWASAKI Heavy Industry
KIRLOSKAR Oil Engines Ltd.
KUBOTA Corporation
MAZDA Motors
NISSAN Shatai
PATAC
PH Valeo
ROTEM
STEYR India
STX Engine
TATA DAEWOO
HYUNDAI Europe
IAMT
IAV
IKA RWTH Aachen
INA-Holding Schaeffler KG
IVM Automotive
Jaguar LandRover
KEIPER Recaro
KNORR Bremse
Kreis Consultancies
KRONES AG
KTM
LIEBHERR
LOGOMOTIVE
L‘Orange GmbH
MAHLE International
MAHLE Motorsport
MAHLE Powertrain
MAN Diesel A/S
MBtech Bohemia sro
Mercedes AMG
Mercedes Benz HPE
MERKLE & PARTNER
MOVENTAS Oy
NABI
NISSAN NTCE
PANKL
PRISMA Engineering
SAS ingeneurbüro ag
SAUER DANFOSS
SCHULER Pressen
SIEMENS AG A&D LD
SIEMENS VAI
SKODA Vyzkum s.r.o.
Stadler Rail
STILL GmbH
Streicher Ing. DL
TECOSIM GmbH
VOITH Turbo Lokomotivtechnik
Westfalia Automotive
TOYOTA Body
TOYOTA Drivetrain
TOYOTA Motorsport
TOYOTA Powertrain
TOYOTA Industries Corporation
YAMAHA MOTOR Co. Ltd.
YOROZU
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FEMFAT User‘s Worldwide – Education &
CooperationUniversity LICENCES
Bergische Univ. Wuppertal, Prof. Yang (Ger)
Bundeswehr Universität München (Ger)
DIEM Universita di Bologna (I)
Dong-A. University, Prof. Joo (ROK
FH Wiener Neustadt, G. Pramhas (Aut)
FH Zwickau, Prof. Gärtner (Ger)
FHT Esslingen, Prof. Greuling (Ger)
FH Wels, Prof. Steiner (Aut)
GH Duisburg, Prof. Nowack, Prof. Haibach (Ger)
GH Kassel, Prof. Klein (Ger)
Gyeongsang University, Young Jin Hwang (ROK)
Hanseo University, Jin Bong Kim (ROK)
IFUM Universität Hannover, J. Schrödter (Ger)
Inje University, Prof. Beom-Keun Kim (ROK
KTH - Stockholm, Prof. Bäcklund (Swe)
Kangwon National University, D.Ph Kim (ROK)
Kyusu Inst. Of Technology (JP)
MU Leoben, Prof. Eichlseder (Aut)
RWTH Aachen, Prof. Wallentowitz (Ger)
Shonan Inst. of Techn., Prof. Shimoda (JP)
Seoul National University (ROK)
Tokyo Metropolitan College, PhD Tamiya (JP)
TU - Brno, Prof. PÍŠTEK (CZ)
TU - Chiba, Prof. Sato (JP)
TU - Clausthal, Prof. Zenner (Ger)
TU - Darmstadt, Prof. Vormwald (Ger)
TU - Dresden, Prof. Kotte (Ger)
TU - München, Prof. Hoffmann (Ger)
TU - Paderborn, Prof. Hahn (Ger)
TU - Stuttgart (Ger)
TU - Vienna, Prof. Rammerstorfer (Aut)
University of Ljubljana, Prof. Fajdiga (Slo)
Cooperation LICENCES
ALTAIR (Hypermesh) (USA, Ger)
ANSYS Inc. (ANSYS) (USA)
BETA CAE (ANSA, META) (Gr)
CADFEM (ANSYS) (Ger)
FE-Design (TOSCA) (Ger)
Function Sim (Recodyn) (Ger, ROK)
ABAQUS Inc. (ABAQUS) (USA)
INPRO GmbH (INDEED) (Ger)
INTEC GmbH (SIMPACK) (Ger)
INTES (PERMAS) (Ger)
IST GmbH (FIRST) (Ger)
T-Systems (MEDINA) (Ger)
Dansk Norsk Veritas (KMB) (Nor)
Hydro Aluminium (KMB) (Nor)
Kongsberg Automotive (KMB) (Nor)
Raufoss (KMB) (Nor)
SINTEF (KMB) (Nor)
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Steyr 1997
FEMFAT User Meetings international & local
Steyr 1999Steyr 2001
Tokyo 2006
Tokyo 2004
Seoul 2005 Seoul 2006
Detroit 2006
Steyr 2005
Steyr 2003
Detroit 2004
Nagoya 2008
Detroit 2008
Steyr 2009
Steyr 2007
Shanghai 2010Seoul 2009