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Durability Evaluation of Tipper Cabin through Virtual Multi-Axis Cab Shake Test
Srinivas Kurna
Ashutosh Dubey
Durability Evaluation of Tipper Cabin through Virtual Multi-Axis Cab Shake Test
Objective
Life Evaluation and Underbody Design finalization of Truck Cabin for Tipper
applications
Based on Fatigue Correlation between Virtual Transient Simulation and 5-Axis Rig
Test.
To validate Life of Cab BIW & Suspensions, reducing physical endurance testing
to minimum.
Durability Evaluation of Tipper Cabin through Virtual Multi-Axis Cab Shake Test
Challenges:
Test Rig setup has been simulated along with Cabin and Truncated portion of
Chassis for calculating the Life Using FEMFAT.
Multiple design iterations life calculations using FEMFAT to reduce the cost for
several physical validations.
Durability Evaluation of Tipper Cabin through Virtual Multi-Axis Cab Shake Test
Methodology:
Life
Evaluation
Rig Test
CAE
FEMFAT
Fatigue Life
Fatigue Life
Life Correlation
Correlated FE Model
Design Iterations
Pass
Optimized Design
Durability Evaluation of Tipper Cabin through Virtual Multi-Axis Cab Shake Test
Methodology:
Duty Cycles generated from Tipper SLDA is used for 5-Axis Cab shake rig and Virtual Simulation
have been applied in CAE model, similar to test rig setup.
Four vertical excitations have been applied on chassis through 4 posters of test rig. One
longitudinal excitation is also applied to simulate longitudinal loads.
Test rig setup has been simulated and correlated in CAE model
Design Iterations are done Virtually and Life Target achieved through FEMFAT evaluation
Design Finalized virtually is validated by Rig Test & Vehicle Endurance No Failures observed
Durability Evaluation of Tipper Cabin through Virtual Multi-Axis Cab Shake Test
Channel
Max
Trans Max
Transient
Stresses
Fatigue Life
Modal
Stresses
Participation
Factors
Fatigue Life
Durability Evaluation of Tipper Cabin through Virtual Multi-Axis Cab Shake Test
Durability Evaluation of Tipper Cabin through Virtual Multi-Axis Cab Shake Test
Durability Evaluation of Tipper Cabin through Virtual Multi-Axis Cab Shake Test
Very good correlations have been achieved between the Test Rig vs. Virtual
simulation results in Displacement/Strain time domain.
Durability Evaluation of Tipper Cabin through Virtual Multi-Axis Cab Shake Test
Measured Strain Damage vs. CAE Damage Values Graph over all Strain Gages
CAE Relative Damage
5
Relative damage
4
3
2
1
0
0
10
11
12
13
14
15
16
It can be observed from the above relative damage graph that damages in the CAE
results are similar to those in rig. However, they are on slightly higher side.
Therefore, CAE will have conservative results for the cabin life calculation.
Durability Evaluation of Tipper Cabin through Virtual Multi-Axis Cab Shake Test
Conclusions:
Fatigue life analysis results through FEMFAT correlates well with rig testing
results. This has improved confidence on virtual analysis, thereby helped in
reducing rig testing and vehicle endurance testing.
This methodology has become standard practice in VECV. We are now using
same methodology for new vehicle chassis validation also.
Since Fatigue life correlation is very good, we have significantly reduced the
number of physical rig tests as well as vehicle endurance test.