13th World Congress in Mechanism and Machine Science, Guanajuato, Mxico, 19-25 June, 2011

IMD-123

Durability tests
M. Jimnez* Volkswagen de Mxico Puebla, Mxico J. Martnez SEPI Zacatenco IPN DF, Mxico

Abstract In a development process product the validation tests are important to know the performance, safety and durability of the components in different load conditions in order to demonstrate the performance of the final product prior to its release. Products must be designed and tested for fatigue resistance over large range of populations considering the scatter between drivers, weather, road conditions and different route profiles. The purpose of this work is present a general process for fatigue test with a iteration process, beginning with data acquisition, data analysis and finally accelerated test. At the end of this work is showed an example for reproduce a dashboards durability test, the process is data acquisition from a specific points in four post test rig, the design of device for mounting alone the test part for two requirements 0-35Hz and 0-50Hz, the iterative process and signal analysis for evaluate the damage in order to get the track for reproduce the damage in a test stand.
Keywords: Durability, Data Acquisition, Fatigue Analysis, Damage.

The durability assessment begins defining the critical points for stress or strain, actually is used Finite Element Analysis for know those critical points that have to be instrumented (fig.2) and is do it an acquisition in roads or proving grounds driving a vehicle, the signal obtained is analyzed for calculate the damage, with this acquisition the collective is build from different route profiles and different drivers.

(a)

(b)

Introduction The assessment of durability tests is based in damage that considering loads and the mechanical properties of the material (fig 1). In S-N curves is important adjust the values considering material properties, surface finish, test part dimension. In other way it is necessary a method for quantify the loads and the damage applied to the component, in this work is used the rainflow method.
Loads Geometry Material

(c) (d) Figure 2.Component of frontal axle (Steeting knuckle) (a) Model, (b)FEM simulation, (c)FEM results, (d)Instrumented part .

Counting Method (Rainflow)

S-N Curve

The durability tests are designed with this target of requirement of fatigue life. There are two common ways for reproduce this damage in test stand: constant amplitude or variable amplitude, the goal of these tests are correlate failure mode using an equivalent damage accelerating development process and achieve more repeatable test results. Figure 3 shows a track control arms test stand for constant amplitude.

Damage. .

Fatigue life Figure 1 General Process in fatigue assessment moises.jimenez@vw.com.mx jomartinezt@ipn.mx 1 13th World Congress in Mechanism and Machine Science, Guanajuato, Mxico, 19-25 June, 2011

Figure 3. Test stand for fatigue test. 1

13th World Congress in Mechanism and Machine Science, Guanajuato, Mxico, 19-25 June, 2011

IMD-123

The control of these tests can be for displacement or force in this case is a force that apply the equivalent damage that in fatigue life in an accelerated way using only a critical value, but do it without the requirement of test a complete car and with the advantage to do it in a less time. It is important to know all the information about the test: loads, materials failure criterium, damage at specific duration an equivalent value between cycles versus kilometers. To generate data useful for fatigue designs using the stress-life approach, stress-life fatigue tests are usually carried out on several specimens at different fully reversed stress amplitudes over a range of fatigue lives for identically prepared specimens. The fatigue test data are often plotted on either semilog or log-log coordinates. Figure 4 shows a typical fatigue data plotted on semilog coordinates. In this figure, the single curve that represents the data is called the S-N curve or the Whler Curve. When plotted on log-log scales, the curves become linear. The portion of the curve or the line with a negative slope is called the finite life region, and the horizontal line is the infinite life region. The point of this S-N curve at which the curve changes from a negative slope to a horizontal line is called the knee of the S-N curve and represents the fatigue limit or the endurance limit.

is generally regarded as the method leading to better predictions of fatigue life. Rainflow cycle counting is a technique for determining closed hysteresis loops in the stress-strain response of a material., a closed hysteresis loop represents a cycle of loading, which fatigue damage is calculated. An observation of the behavior of metals is that when loaded past the yield point of the material, unloaded, then re-loaded to an even higher stress level, the material "remembers" the original loading curve and follows it until the next unloading event, as illustrated in figure 5. The unloading and reloading path is called a hysteresis loop. It is possible to even have many small loops nested inside of larger loops, with each unloading point remembered until the load is reversed and the loop is closed.

Fig 5. Hysteresis loop Stress Vs Strain

Although these hysteresis loops are easily visualized by examining the stress-strain response of the material, it is only the change in the load, stress, or other independent quantity that determines if the load reverses and loops remain open or closed. Therefore, an analysis of only the load history can identify hysteresis loops. A data reduction method is a mapping acting on the set of time series and transforming it into the set of reduced data as shown in the figure below, for the case of rainflow counting:
Figure 4 Schematic of an S-N curve for steels.

Fatigue life data exhibit widely scattered results because of inherent microstructural inhomogeneity in the materials properties, differences in the surface and the test conditions of each specimen, and other factors. In general the variance of log life increases as the stress level decreases. This plot is used for predict the fatigue life comparing the loads an the number of repetitions for do this process way the signal has to be analyzed for counting the cycles and with the information of the material calculate the damage of each cycle loads the rainflow counting method
2

Fig. 6: Data reduction is a non-injective mapping

13th World Congress in Mechanism and Machine Science, Guanajuato, Mxico, 19-25 June, 2011

IMD-123

The mapping is such that more than one time series can be mapped into the same rainflow matrix. For a given reduction method, two time series are called equivalent (f g), if they are mapped to the same reduced data element (e.g. the same rainflow matrix). We will call a data reduction method a damage based data reduction method if all load histories that are mapped to the same reduced data element lead to the same damage. In terms of fatigue analysis, different time series with equal rainflow matrices (and thus equal fatigue damage) can be considered equivalent time series, figure 8 shows the time history signal and figure 9 its respective rainflow matrix.

This is the target for devices design, the first natural frequency has to be greater that this value in order to prevent resonances. The first and most common step is build a CAD model with the necessary fixtures for the test part, figure 10.
Frontal Panel support

Device

Fixture for cylinder Figure 10. Device Design model in CATIA.

Figure 8, Time history of the signal time vs Force.

All the values near of the diagonal are noise and dont have influence in the durability of the test part.

This model was sended from Catia V5 to Hypermesh in order to generate the FEM model using linear elements 2D (Tria and Quad) and 3D (Hexa and Penta), then the FEM model was sended to Abaqus V6.8. The material is structural steel A36 and its mechanical properties are: Elasticity modulus(E) = 210GPa = 210,000N/mm2, Poissons coefficient () = 0.3 Density = 7.85e-9ton/mm3 The boundary conditions were constraints all nodes in the bottom face in 6 Degress Of Freedom (the face that is in contact with the fixture). The first and second natural frequencies are presented in Fig. 11.

Figure 9,Rainflow matrix.

Implementation and results

(a) (b)

Durability test of frontal panel(dashboard). Now it is show the process to develop a test of frontal panel, the process begin with the acquisition in a body car tested in four post test rig, the signal analyses, the iterative process until found the signal in order to reproduce an equivalent damage in a hydraulic cylinder, and is showed a design of device with the requirements in frequencies and mechanical strength. Modal analysis for prevent resonances in new test stand of frontal panel (dashboard) The first step for define the boundary conditions was evaluate the range of frequencies in the signal obtaining a frequencies range between 0-35Hz.

Figure 11. Modal results in FEM simulation (a)first natural frequency 40.923Hz (b) second natural frequency 43.173Hz.

It was performed a experimental test, it was used it an accelerometer triaxial for the response and an uniaxial accelerometer for reference. Figure 12.

Uniaxial accelerometer

Triaxial accelerometer

Figure 12. Instrumentation for modal analysis. 3

13th World Congress in Mechanism and Machine Science, Guanajuato, Mxico, 19-25 June, 2011

IMD-123

After mount the device on the hydraulic cylinder of +/-125mm of displacement we generate a sweep on the servocontroller MTS Flex test GT from 0 to 50Hz with a step of 1Hz/sec the amplitude for the test is +/-2mm. The results of the experimental test are showed in figure 13, we found the first natural frequency at 41.4Hz, and the second natural frequency at 43.7 Hz

43.7Hz 41.4Hz

Figure 15. Topology optimization results Figure 13. Normal modes in direction Z

After validate the process the signal was changed and the range of frequencies increase from 35 to 50Hz, thats why was performed a topology optimization for reduce the material and with the requirement for the first natural frequency up to 50Hz it was applied the next process (fig 14).
Fem Model Define design Variables.
-Volume, Area to work

From the topology results is modified the model for get the first mode up of 50Hz, the final model is showed in figure 17 without material where is not necessary and putting some material for reinforced the device according with the last results, and it was performed and modal simulation.

Response
-Volume, Partial or total. -Frequency

(a)
Define objective.
-Minimize Volume.

(b)

Design constraint
-Frequency lower limit.

Figure 16. Modal results in FEM simulation (a)first natural frequency 63.95Hz (b) second natural frequency 69.6Hz.

Run optimization
No Yes

OK
Feasible design

Export result to CAD Software in IGES format. An generate a new Model

With this FEM model it was obtained the first natural frequency is 63.95 Hz and the second natural frequency is found it in 69.96 Hz (fig 16), the physical model is showed in figure 17.

Figure 14. Optimization process

In the FEM model was defined two kinds of areas nondesign(red) and design (brown) the latter is where the software can remove material. The parts in red are non design areas because these areas are the points for joint and fix the device and the dashboard, all the brown area is where we can have material or not, the objective of this topology simulation is reduce the volume with a constraint of the lower frequency greater than 50 Hz. The results are showed in figure 15 it is showed how the software reduce the volume.
4 Figure 17. Device with test part (frontal panel).

13th World Congress in Mechanism and Machine Science, Guanajuato, Mxico, 19-25 June, 2011

IMD-123

The signal for dashboards test was obtained with an accelerometer uniaxial for measure the acceleration in Z direction in a four post test rig Figure 18.

others test parts depends on the stiffness and the test conditions for example the temperature. Applying the response and the desired signal start the iteration process, where every iteration approach the driver to obtain the desired response in the test part . Figure 20 shows the signal in time domain, the signal in black is the target the signal in green is the drive that is obtained in each iteration in this case is necessary more amplitude, for apply the same forces to the test part. Figure 21 shows a zoom between 0 to 22 seconds. Every iteration the signal is approaching to the target, but is necessary review the signal in frequency domain figure 22 for analyze if the drive has resonances if this the case is necessary to go back many iterations and apply different regions or filters until reach the same response.

Figure 18 Four post test rig.

After measure one track, was applied two integrals to the signal in order to get the displacement. Figure 19.
40 30

20

10
mm

-10

-20

-30

-40 0 100 200 300 400 [sec] 500 600 700 800 905

Figure 19. Time history of the Signal from acquisition.

With this signal its necessary to perform a methodology for have the ability to reproduce the same damage in a test stand where we need a signal but the driver can not be the same because only applying the signal we cant get the same results due to in the car we have tires, suspension system that contribute in some cases increase the amplitude in other eliminate some component of the signal the fixtures in other words we have a nonlinear system this is why is necessary to perform a iteration process in order to get the driver for apply the same test conditions. The process begin analyzing and editing the signal: resampling to 204.8Hz analyze all the signal for eliminate noise that not contribute to the damage but affect the test because it can contribute to resonances. After that is necessary a random noise and is used it to drive the test system and measure the response. The response information is used to calculate the system model, every test need a different model due to every test part has its characteristic response and is different than
5

Figure 20. Iteration process in time domain.

Figure 21. Zoom to the Iteration process in time domain.

13th World Congress in Mechanism and Machine Science, Guanajuato, Mxico, 19-25 June, 2011

IMD-123

(a)

(a)

(b) Figure 23.Damage Analyzes, (a) Around 90% of the damage and (b) around 100% of the damage

Conclusions Damage concept is used to correlate the accelerated test to proving ground or road loading in a laboratory with this tools the validation is do it in less time, a detailed signal analyses for calculate the equivalent damage is need it for know the correlation between cycles versus kilometers. Modern servo hydraulic equipment permits the application of virtually any load history and can therefore be used to determine service life. The process presented shows an option for test different cars parts without the requirement to mount it in the car.
(c) Figure 22. Iteration process in frequency domain. (a) Initial iteration, (b) middle iteration and (c) final drive

(b)

The iteration process is an option for reproduce equivalent damage with hydraulic equipment in terms of forces and displacements, doing the test faster and cheaper. References
[1] Yung-Li Lee, Jwo Pan, Richard B. Hathaway, Mark E. Barkey, Fatigue Testing and Analysis, Elsevier Buiterworth Heinemann, 2005. [2] Les Pook, Metal fatigue, pages 1-55, Springer 2007 [3] Jimnez Martnez Moiss, Martnez Trinidad Jose, Mechanical optimization of devices for durability test, Congreso Nacional de Ingeniera Electromecnica y de Sistemas, IPN 2010. [4] Abaqus referente Manual V6.8 [5] Optistruct reference Manual V10.0 [6] RPC Pro application reference Manual release 4. [7] LMS Tecware reference Manual V2.14.

Sometimes the signals are not equal in higher frequencies but is balanced with a stronger signal in lower frequencies fig 22c, when we are near to the desired data is necessary to compare both signals for analyze if it is applying the same damage, for measure this damage is necessary to do an extensive analyze for compare both signal, it can be used LMS Tecware for compare it. Figure 23 shows two analyzes, the first column is a counting method, the second column is PSD and the third column is the damage, in figure 23a the damage is around 90%, and the figure 23b is around 100% of the damage, the red signal is the target the green signal is the response with a filter and the blue signal is the response without filter, the analyzes of all this information defined if we reach the drive or we have to improve the response.
6