nafems - fenet workshop 13-14 june 2002, zurich€¦ · nafems - fenet workshop 13-14 june 2002,...
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NAFEMS NAFEMS -- FENET Workshop FENET Workshop 1313--14 June 2002, Zurich14 June 2002, Zurich
Fatigue Life Improvement of an Innovative Suspension System
Nawal Nawal K K PrinjaPrinja BSc, MSc, PhD, BSc, MSc, PhD, FIMechEFIMechETechnical ManagerTechnical Manager
NNC LimitedNNC LimitedUKUK
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Models for the Automotive Industry
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ContentsContents
IntroductionIntroduction
MethodologyMethodology
Model GeometryModel Geometry
Stress AnalysisStress Analysis
Fatigue AssessmentFatigue Assessment
RecommendationsRecommendations
ConclusionsConclusions
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"We are testing are 5th prototype. What "We are testing are 5th prototype. What magic can you do?"magic can you do?"
FE ModellingFE Modelling
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IntroductionIntroduction
Scope of WorkScope of WorkTo use Finite Element analysis to improve the fatigue life oTo use Finite Element analysis to improve the fatigue life of the f the Suspension Assembly.Suspension Assembly.
Objectives
•Failure assessment of Mark V Suspension System.•Demonstrate capabilities of complex FE analysis techniques to support design development.•Suggest design improvements.•Streamline design development process.
HistoryHistoryNew designs for suspension systems for lorries were being deNew designs for suspension systems for lorries were being developed veloped by conventional test and trial methodby conventional test and trial method
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MethodologyMethodology
Convert CAD geometry to FE modelConvert CAD geometry to FE model–– midmid--surfaces/volumessurfaces/volumes
–– meshingmeshing
–– boundary conditions/loadingboundary conditions/loading
–– validationvalidation
Stress AnalysisStress AnalysisFatigue AnalysisFatigue AnalysisAssessmentAssessment
–– Steel componentsSteel components
–– Welded jointsWelded joints
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Main ComponentsMain Components
Assembled in parts for easier manufacturingAssembled in parts for easier manufacturing
Axle CL
Wrap Plate
Side Plate
Arm
Pivot
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Model Geometry Model Geometry -- PartsParts
Bush/Pivot
Arm
SidePlate
WrapPlate
Spring Platform
Axle
Damper
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Model Geometry Model Geometry -- From CAD to FEFrom CAD to FE
IGES File - Volumes
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Modelling AssumptionsModelling Assumptions
16°Orientation of Side PlateOrientation of Side PlateAngle @ start of test 20°Angle @ start of test 20°
Axle to Wrap Plate Axle to Wrap Plate connectionconnection-- No frictional No frictional contact Plug weld to
axle
Plug weld to axle
MPCconnection to axle
MPCconnection to axle
contact
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Model Geometry Model Geometry -- Mesh GenerationMesh Generation
Solidelements
Shellelements
Pipe elements
Springelements
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Modelling of Welded JointsModelling of Welded Joints
Welds represented as Beam ElementsWelds represented as Beam Elements
Arm to Pivot
Arm to Cover Plate
Arm to Damper
Arm to Side Plate
Arm to Spring Platform
Wrap Plate to Wrap Plate
Side Plate to Wrap Plate
Side Plate to Side Plate
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Mesh Generation Mesh Generation -- Full ModelFull Model
86438 elements150089 nodes
35,000 load cycles
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Stress AnalysisStress Analysis
Linear ElasticLinear Elastic
Boundary Conditions Boundary Conditions
44 LoadcasesLoadcases–– Roll ManoeuvreRoll Manoeuvre
–– Tramp ManoeuvreTramp Manoeuvre
–– Scrub ManoeuvreScrub Manoeuvre
–– 1.75g Bump Manoeuvre1.75g Bump Manoeuvre
Material PropertiesMaterial Properties
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Stress Analysis Stress Analysis -- Boundary ConditionsBoundary Conditions
F
F
Nearside (RH)
Offside (LH)
x
x
y
y
ry
ry
rx
rx
rz
rz
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Stress Analysis Stress Analysis -- Material PropertiesMaterial Properties
Part Young’s Modulus Poisson’s Ratio
Arm 203GPa 0.3Spring Platform " "Cover Plate " "Damper " "
Side Plate " "Wrap Plate " "
Pivot " "
Welds 406GPa "
Axle 203GPa "
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Stress Analysis Stress Analysis -- LoadcaseLoadcase 11
Roll ManoeuvreRoll Manoeuvre
–– StartStart Step 1Step 1MidMidEndEnd
–– RolloverRollover Step 2Step 2
–– RolloverRollover Step 3
44.15kN 44.15kN
AxleAir Springs Loads
Wheel Loads
77.15kN 11.15kN30.86kN 4.46kN
77.15kN11.15kN30.86kN4.46kN
Step 3
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Stress Analysis Stress Analysis -- LoadcaseLoadcase 22
Tramp ManoeuvreTramp Manoeuvre
–– StartStart Step 1Step 1MidMidEndEnd
–– LH BumpLH Bump Step 2Step 2
–– RH BumpRH Bump Step 3
44.15kN 44.15kN
AxleAir Springs Loads
Wheel Loads
83.91kN 4.39kN
83.91kN4.39kN
Step 3
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Stress Analysis Stress Analysis -- LoadcaseLoadcase 33
Scrub ManoeuvreScrub Manoeuvre
–– StartStart Step 1Step 1MidMidEndEnd
–– LH +LH +veve Step 2Step 2
–– LH LH --veve Step 3
44.15kN 44.15kN
AxleAir Springs Loads
Wheel Loads
44.15kN 44.15kN26.49kN 26.49kN
44.15kN44.15kN26.49kN26.49kN
Step 3
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Stress Analysis Stress Analysis -- LoadcaseLoadcase 44
1.75g Bump Manoeuvre1.75g Bump Manoeuvre
–– StartStart Step 1Step 1EndEnd
–– PeakPeak Step 2
44.15kN 44.15kN
AxleAir Springs Loads
Wheel Loads
77.26kN 77.26kN
Step 2
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LoadcaseLoadcase 1: Roll Manoeuvre1: Roll Manoeuvre
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Stress Analysis Stress Analysis -- Model ValidationModel Validation
Start Condition Start Condition -- Sum of Vertical ForcesSum of Vertical Forces
27.4kN
27.4kN
44.2kN
44.2kN
8.9kN
8.9kN
7.7kN
7.7kN
Applied vertical forces
Vertical reaction forces in springs
∑ = ∑
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Stress Analysis Stress Analysis -- ResultsResults
Roll Manoeuvre Roll Manoeuvre -- Displaced ShapeDisplaced Shape
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Stress Analysis Stress Analysis -- ResultsResults
Rollover LH Rollover LH -- Arm/Pivot Arm/Pivot -- TRESCA StressTRESCA Stress
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Stress Analysis Stress Analysis -- ResultsResults
Rollover LH Rollover LH -- Spring Platform Spring Platform -- TRESCA StressTRESCA Stress
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Stress Analysis Stress Analysis -- ResultsResults
Rollover LH Rollover LH -- Side Plate Side Plate -- TRESCA StressTRESCA Stress
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LoadcaseLoadcase 2: Tramp Manoeuvre2: Tramp Manoeuvre
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Stress Analysis Stress Analysis -- ResultsResults
Tramp Manoeuvre Tramp Manoeuvre -- Displaced ShapeDisplaced Shape
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Stress Analysis Stress Analysis -- ResultsResults
Tramp LH/RH Bump Tramp LH/RH Bump -- Arm/Pivot Arm/Pivot -- TRESCA StressTRESCA Stress
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Stress Analysis Stress Analysis -- ResultsResults
Tramp LH/RH Bump Tramp LH/RH Bump -- Spring Platform Spring Platform -- TRESCA StressTRESCA Stress
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Stress Analysis Stress Analysis -- ResultsResults
Tramp LH/RH Bump Tramp LH/RH Bump -- Side Plate Side Plate -- TRESCA StressTRESCA Stress
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LoadcaseLoadcase 3: Scrub Manoeuvre3: Scrub Manoeuvre
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Stress Analysis Stress Analysis -- ResultsResults
Scrub Manoeuvre Scrub Manoeuvre -- Displaced ShapeDisplaced Shape
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Stress Analysis Stress Analysis -- ResultsResults
Scrub LH Scrub LH --veve -- Arm/Pivot Arm/Pivot -- TRESCA StressTRESCA Stress
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Stress Analysis Stress Analysis -- ResultsResults
Scrub LH Scrub LH --veve -- Spring Platform Spring Platform -- TRESCA StressTRESCA Stress
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Stress Analysis Stress Analysis -- ResultsResults
Scrub LH Scrub LH --veve -- Side Plate Side Plate -- TRESCA StressTRESCA Stress
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LoadcaseLoadcase 4: 1.75g Bump Manoeuvre4: 1.75g Bump Manoeuvre
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Stress Analysis Stress Analysis -- ResultsResults
1.75g Bump Manoeuvre 1.75g Bump Manoeuvre -- Displaced ShapeDisplaced Shape
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Stress Analysis Stress Analysis -- ResultsResults
1.75g Bump 1.75g Bump -- Arm/Pivot Arm/Pivot -- TRESCA StressTRESCA Stress
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Stress Analysis Stress Analysis -- ResultsResults
1.75g Bump 1.75g Bump -- Spring Platform Spring Platform -- TRESCA StressTRESCA Stress
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Stress Analysis Stress Analysis -- ResultsResults
1.75g Bump 1.75g Bump -- Side Plate Side Plate -- TRESCA StressTRESCA Stress
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Stress Analysis Stress Analysis -- ResultsResults
Critical Locations of Peak StressesCritical Locations of Peak Stresses
Arm, Side Plate and Welds
Arm and Spring Platform
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AssessmentAssessment
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Assessment IssuesAssessment Issues
Three failure mechanisms are relevant :-
Crack initiationCrack initiation–– Fatigue assessment using BS5400 rulesFatigue assessment using BS5400 rules
Crack PropagationCrack Propagation–– Fracture mechanics using R6 procedureFracture mechanics using R6 procedure
Cyclic plasticity causing incremental collapseCyclic plasticity causing incremental collapse–– Shakedown criteriaShakedown criteria
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Fatigue Assessment Fatigue Assessment -- MethodologyMethodology
Parent Material and WeldsParent Material and Welds
–– BS5400 Part 10 & BS7608BS5400 Part 10 & BS7608
–– Critical sample stress locations assessedCritical sample stress locations assessed
–– Alternating stress calculated using FORTRAN programmeAlternating stress calculated using FORTRAN programme
–– Predicted number of cycles to failure calculatedPredicted number of cycles to failure calculated
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Fatigue Assessment of Parent MaterialFatigue Assessment of Parent Material
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Assessment Assessment -- Stress HistoryStress History
Example of Stress Range Selection Example of Stress Range Selection
Stress History - Element 480Integration Point 1
-600
-400
-200
0
200
400
600
800
Roll (s2) Roll (s3) Tramp (s2) Tramp (s3) Scrub (s2) Scrub (s3) 1.75g (s1) 1.75g (s2)
Manoeuvre
Trescas11s22s12
Multi-axial non-proportional stress-strain state
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Fatigue Assessment Fatigue Assessment -- ResultsResults
Arm Arm -- Element 480Element 480
Manoeuvre
Roll
Tramp
Scrub
1.75g
Detail Class
W (G)
W (G)
W (G)
W (G)
Alternating Stress(MPa)
290
339
14
122
Stress Range (MPa)
580
678
28
244
Predicted Cycles to Failure(N)
1.9e3 (2.9e3)
1.2e3 (1.8e3)
1.6e7 (2.6e7)
2.5e4 (3.9e4)
Usage
16.8 (11.0)
26.7 (17.5)
0.0 (0.0)
1.3 (0.8)
44.8 (29.3)∑
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Fatigue Assessment Fatigue Assessment -- ResultsResults
Arm Arm -- Fatigue UsageFatigue Usage
NS : E480 : W (G) : U=44.8 (29.3)
OS : E60600 : W (G) : U=3.8 (2.4)
OS : E60988 : W (F2) : U=2.7 (0.2)
OS : E601798 : B : U=0.2
OS : E61016 : W (G) : U=24.5 (15.6)
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Fatigue Assessment Fatigue Assessment -- ResultsResults
Arm Arm -- Fatigue UsageFatigue Usage
OS : E108787 : W (G) : U=7800 (5300)
OS : E136505 : W (G) : U=5300 (3500)
OS : E105227 : W (G) : U=550 (350)
OS : E143459 : W (G) : U=23 (15)
OS : E141166 : W (G) : U=43 (28)
OS : E141977 : W (G) : U=1.2 (0.8)
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Spring Platform Spring Platform -- Fatigue UsageFatigue Usage
OS : E62458 : W (F2) : U=25.2 (3.5)
OS : E62302 : W (G) : U=2.3 (0.4)
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Fatigue Assessment of WeldsFatigue Assessment of Welds
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Fatigue Assessment of WeldsFatigue Assessment of Welds
Plug Weld Adjacent Element 480 (Arm side of weld only) Plug Weld Adjacent Element 480 (Arm side of weld only)
Manoeuvre
Roll
Tramp
Scrub
1.75g
Detail Class
W
W
W
W
Alternating Stress(MPa)
137
132
6
67
Stress Range (MPa)
273
263
12
133
Predicted Cycles to Failure(N)
1.8e4
2.0e4
2.1e8
1.6e5
Usage
1.8
1.6
0.0
0.2
3.6∑
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Why Fatigue Failure?Why Fatigue Failure?
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Why Fatigue Failure?Why Fatigue Failure?
Load PathLoad Path
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Why Fatigue Failure?Why Fatigue Failure?
Large stresses from side plate to armLarge stresses from side plate to arm
High longitudinal compressive stress
High longitudinal tensile stress
High vertical tensile stress
High vertical compressive stress
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Why Fatigue Failure?Why Fatigue Failure?
Action of plug welds on armAction of plug welds on arm
High vertical tensile stressHigh vertical compressive stress
High longitudinal compressive stress
High longitudinal tensile stress
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Why Fatigue Failure?Why Fatigue Failure?
Stress flow dictated by Stress flow dictated by –– loading mechanismloading mechanism
–– Shape and location of the plug weldsShape and location of the plug welds
Max. Principal Stress (tension) Min. Principal Stress (comp.)
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Why Fatigue Failure?Why Fatigue Failure?
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Fracture MechanicsFracture Mechanics
R6 used to calculate the critical crack size
Safe
FailCritical Crack Size
Stress intensity, KI
Failure if KI > KICKr = KI / KIC
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Fracture MechanicsFracture Mechanics
Crack Propagation in Arm for Element 480 (top surface)Crack Propagation in Arm for Element 480 (top surface)Vertical (s22) stress assessment Vertical (s22) stress assessment
Manoeuvre
Roll
Tramp
Scrub
1.75g
Critical Crack Size (mm)
3.5
3.6
4.4
3.9
Crack Growth over 32000 cycles (mm)
1.9
1.8
0.1
0.6
Initial Crack Size to Cause Failure (mm)
1.7
1.8
4.3
3.3
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ConclusionsConclusions
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ConclusionsConclusions
Geometric dataGeometric data–– Transfer from CAD to FE worksTransfer from CAD to FE works
–– Provision of shell geometry as midProvision of shell geometry as mid--surfaces and solid as surfaces and solid as volumevolume
Stress AnalysisStress Analysis–– Full test simulation possibleFull test simulation possible
–– Peak stresses identifiedPeak stresses identified
–– Loading mechanism and stress flow understoodLoading mechanism and stress flow understood
cont’d.cont’d.
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ConclusionsConclusions
AssessmentAssessment–– Vertical loading dominantVertical loading dominant
–– Fatigue failure in parent metal and in weldsFatigue failure in parent metal and in welds
–– Allowable stress range ~226MPa for 32,000 cycles for detail clasAllowable stress range ~226MPa for 32,000 cycles for detail class Ws W
–– Local stress concentrations cause failuresLocal stress concentrations cause failures
–– Roll and Tramp manoeuvres cause most damageRoll and Tramp manoeuvres cause most damage
–– Accelerated fatigue testing by using high loads causes plasticitAccelerated fatigue testing by using high loads causes plasticity and y and incremental collapseincremental collapse
–– Functional failure occurs when theoretical fatigue usage factor Functional failure occurs when theoretical fatigue usage factor is 15 or is 15 or moremore
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RecommendationsRecommendations
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RecommendationsRecommendations
SimulationSimulation
Include bracket at the pivoted end for more realistic Include bracket at the pivoted end for more realistic test simulationtest simulationConduct nonConduct non--linear analysis of the linear analysis of the
–– airair--springspring
–– bushbush
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Design ImprovementsDesign Improvements
DesignDesign
Redesign the plug weld connection to avoid peak Redesign the plug weld connection to avoid peak stresses in the lower regionsstresses in the lower regionsInvestigate spring platform local strengtheningInvestigate spring platform local strengtheningRemove the Cover PlateRemove the Cover Plate
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New Design without Side PlateNew Design without Side Plate
Bush/Pivot
Front Arm
WrapPlate
Spring Platform
Axle
Damper
Arm Rear
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Stress Analysis Stress Analysis -- InterpretationInterpretation
Displacement DirectionDisplacement Direction
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Stress Analysis Stress Analysis -- ResultsResults
Tramp Manoeuvre Tramp Manoeuvre -- Stress Contours in Wrap Plate (Front)Stress Contours in Wrap Plate (Front)
s11 s33
s13 Tresca(0 to 345)
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Stress Analysis Stress Analysis -- InterpretationInterpretation
S11 Stress in Axle Front for allS11 Stress in Axle Front for all LoadcaseLoadcase
1.75g Bump
Roll
Scrub
Tramp
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Design ImprovementDesign Improvement
Improve the Improve the cutoutcutout radiiradiiChange the angular orientation of the Side PlateChange the angular orientation of the Side Plate
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Bush/Pivot
Front Arm
WrapPlate
SpringPlatform
Axle
Damper
Arm Rear
Original design
Fatigue life < 20,000 cyclesImproved design
Fatigue life > 35,000 cycles