FEMFAT =Fatigue Analysis by Finite Element Method; · PDF fileMulti Axial Fatigue Analysis F...

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)

© ECS / Disclosure or duplication without consent is prohibited 3

ECS Software Products


Finite Element / Multi Body Simulation

& Fatigue Analysis

Fatigue Test Lab

Engine Test Lab

Drivetrain Test Lab

Test Track

Synergy Analysis / Testing


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


Double lane change

Lateral acc. CabSpeed 60 km/h

Roll angle CabSpeed 60 km/h

Lateral Dynamics (double lane change)

Comparison Rigid/Independent Axle


MBS / FEA + Fatigue Simulation Vehicle Body

Basic FE-MeshLocal remeshing

of spot-joints

Fatigue prediction


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


Simulation: crack initiation at 6 h

Test:

crack detected

after 48 h

Truck Cab Durability Analysis


Test:

crack detected

after 192 hSimulation: crack initiation at 50 h



Test: 12 hSimulation: 1 h

... Contact

affected

area



Detailed Result Output for SPOT Nodes in

VISUALIZER

12

Force based SPOT assessment

Stress based SPOT assessment


Result: damage distribution

MAT 203

MAT 205

Welding modeling

guideline

Chassis Frame, Weldings


Opening in the IHV- tube

5,730,27

0,41

1,86

Comparison FLP - Test bench


Joints of IHV- tubes

29,1

Comparison FLP - Test bench


POWERTRAIN Simulation

Engine/Gearbox Analysis

Durability

Optimization

Acoustics

Cranktrain Dynamics

Geartrain Dynamics


Influences from Production in FEMFAT

Production Processes

Metal Forming

Sand-/ Permanent

Mold CastingDie Casting

Casting

Injection moldingMore to come...

17


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


Correlation with test results

Nominal material

propertiesBoundary layer

model

Test result

Influence from Die Casting on Fatigue Life

19


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:


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

21


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 !


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


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)


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

FEMFAT =Fatigue Analysis by Finite Element Method; · PDF fileMulti Axial Fatigue Analysis F...

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Transcript of FEMFAT =Fatigue Analysis by Finite Element Method; · PDF fileMulti Axial Fatigue Analysis F...