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Durability Assessments ofMotorcycle Handlebars
Ken-Yuan Lin, Jung-Ming Chang, Jui-Hung Wu, Chih-Huang Chang
Automotive Research and Testing Center
Shun-Hui Chang, Jiun-Ren Hwang
National Central University
Chin-Ping Fung
Chung Cheng Institute of Technology
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CONTENT
Introduction
Objective
Theory
Methods
Results and Discussion
Conclusion
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INTRODUCTION
Motorcycle Industry is one of
the most important industries in
Taiwan.
Fatigue Cracks of motorcycle
structures are sometimes foundto initiate at welded regions
during structural development.
It is necessary to understand
what fatigue analysis approachis suitable for this product.
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OBJECTIVE
The purpose of this study is
to characterize fatigue
behavior of the motorcycle
handlebar, and develop asuitable durability
analysis approach for it.
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THEORY
Influence of Fatigue Life of the Welded Joint :
Geometric Shape, Material Property, Residual Stresses
and Weld Defects.
BS 5400 : Part 10 Standard
Nine Classes : Load Type, Weld Geometry and
Location of Potential Crack Initiation.
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THEORY
When Nf 107, the correlation between fatigue life and nominal
stress is:
where
Nf: fatigue life,
K : constant relating to the mean-line of the statistical analysis
results,
z : number of standard deviations below the mean-line,
s : standard deviation of Log Nf,
m : inverse slope of mean-line log S Log Nfcurve,
Sn
: nominal stress.
nf SLogmzKLogNLog =
BS 5400 :
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THEORY
When Nf> 107, the equation is:
Gurney modified equation was to consider thickness effect.
The modified equations are as follows:
When Nf 107,
When Nf> 107,
t : thickness (mm)
25.022)(t
nf
SLogmzKLogNLog =
25.022
)(
)2(
t
nf
SLogmzKLogNLog +=
nf SLogmzKLogNLog )2( +=
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4. Road Simulation
METHODS
1. Target Component and Target Track
2. Stress Analysis
3. Data Acquisition of Field Test
5. Durability Tests
6. Evaluation of Fatigue Life
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The motorcycle handlebar
The vehicle used in this
study was a 150c.c. scooter
type of motorcycle.
We selected motorcycle
handlebar as the targetcomponent.
1. Target Component and Target Track
METHODS
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The Belgium (Pave) road
The target track is the
Belgium (Pave) road of the
proving ground in ARTC(Automotive Research and
Testing Center in Taiwan).
1. Target Component and Target Track
METHODS
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2. Stress Analysis
The MSC.Nastran finite
element software was adoptedto carry out the stress and
strain analysis and to find out
possible failure locations.
METHODS
Stress distribution of the motorcycle
handlebar (loading angle 26o)
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3. Data Acquisition of Field Test
The Field Strain : Measurement
from the Belgium road Speed : 30 km/hr
Sampling Rate : 1 kHz
Data Recorder: IMC-CRONOS Field test on the Belgium (Pave) road
METHODS
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4. Road Simulation
To obtain the load history
in the durability test.
Strain - remote parameter
control (RPC) technique
Controller - IST-8800
Software - RS-SPiDAR
Motorcycle Handlebar
Servo Hydraulic Actuator
Force input of the durability test
METHODS
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Setup of the durability test
5. Durability Tests
(1x) Strain History : up to 800 hours
(3x, 3.5x, 4x and 4.5x) : within 48
hours
Durability Test : Single Actuator
Periodical Inspection : Crack
Initiation
METHODS
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METHODS
6. Evaluation of Fatigue Life
S-N Approach : EstimatedStress-Life Curves
BS 5400 Approach : the class,
thickness, probable failure ofwelded joint
BS 5400 standard with the
Gurney thickness modification
approach Rainflow cycle counting
Miners damage accumulation
Rainflow cycle counting
Life cycles
Stressrange(MPa)
Estimated stresslife curve of
JIS S25C steel
Stresslife curve of BS 5400
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When the force downward at
an angle of 26o from the
horizontal, the crack was
produced in the weldedregion (area A), where the
handle was welded to the main
pipe.
Stress distribution of the motorcycle handlebar
(loading angle 26o)
1. Analysis of Loading Angle and
Failure Location
26
A
Failure location of motorcycle handlebar in
durability test (loading angle 26o)
RESULTS AND DISCUSSION
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If the angle of force input was
increased to 36o from the
horizontal, The actual cracks
would initiate at the welded
region - area B.
Stress distribution of the motorcycle handlebar(loading angle 36o)
36
B
Failure location of motorcycle handlebar in
durability test (loading angle 36o)
1. Analysis of Loading Angle andFailure Location
RESULTS AND DISCUSSION
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Failure location of the handlebar
in the full vehicle durability test
1. Analysis of Loading Angle andFailure Location
In conclusion, the loading
direction of the servo hydraulicactuator for the follow-up
durability tests was defined at
26 from the horizontal.
RESULTS AND DISCUSSION
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Response strain history in the
durability test (3x magnification)
A portion of original and reproduced
strain histories (3x magnification)
reproduced by remote parameter control
technique
2. Evaluation of Fatigue Life
RESULTS AND DISCUSSION
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Number of Magnification of
Strain History
R.M.S. of OriginalStrain
( g )
R.M.S. of ReproducedStrain
( g )
Error
(%)
3 279.2 275.6 1.29
3.5 325.7 321.3 1.35
4 372.2 366.9 1.42
4.5 418.8 412.5 1.50
Note: R.M.S. (root mean square)
Results of road simulation
2. Evaluation of Fatigue Life
RESULTS AND DISCUSSION
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The failure location at welded region and the G class of BS 5400 standard
2. Evaluation of Fatigue Life
RESULTS AND DISCUSSION
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Specimen No.Ultimate Strength
(MPa)Yield Strength
(MPa)Elongation (%)
1 537.9 506.8 14.8
2 532.5 507.4 17.0
3 548.2 521.7 15.8
Average 539.5 512.0 15.9
Results of tensile tests for motorcycle handlebar are: ultimate strength
= 539.5 MPa, yield strength = 512.0 MPa, elongation = 15.9%.
2. Evaluation of Fatigue Life
RESULTS AND DISCUSSION
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RESULTS AND DISCUSSION
Fatigue Life (blocks)Strain History
(Number ofMagnification) Experiment Traditional S-NApproach
BS 5400
Standard BS 5400 with
Gurney Thickness
Modification
1 56612300 3426 19374
2 424982 389 2126 3 1418 51703 115 625
3.5 756 24616 72.8 396 4 395 13120 48.6 265
4.5 129 8625 48.3 263
2. Evaluation of Fatigue Life
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CONCLUSION
By the CAE analysis and experimental results, the loadingdirection of the servo hydraulic actuator for the
durability test was defined at 26 from the horizontal.
? BS 5400 standard with the Gurney thicknessmodification approach? is suitable to assess the
durability of motorcycle handlebars, the difference
between experiment and prediction is within 2.5 times.
In the future, this approach could be applied to thedurability assessment for weldments of automobiles.
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Thanks for YourThanks for Your
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