Professional Documents
Culture Documents
22 Nov 2017
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Agenda
• Overview of Endurica solutions
• Materials testing for durability
• User Examples
• Caterpillar - Critical Plane Analysis / strain crystallization
• Tenneco – Bushing under radial / axial / conical / torsion loads
• GM – Bushing w/ road loads
• Tire durability analysis
• Live Demo
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Endurica Solutions: Get Durability Right!
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Endurica CL v2.6
MSC Marc
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Characterization Toolbox for Durability
Thermal Module
Core Fatigue Module Quantify dissipative Cyclic Softening Module
Fully Relaxing Behavior from
properties, thermal Quantify Cyclic Softening
both nucleation and fracture
properties, temperature Effects
mechanical perspectives
dependence
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Fatigue Crack Growth Testing
Tear and Fatigue Analyser
dc mm
dN cyc
Intrinsic Strength Analyser Crack growth rate Endurance Limit
Ultimate Strength
mm
108
cyc
J
T0 Tc T 2
m
Intrinsic Strength Option
(>106 cycles)
Energy Release Rate
Quantify endurance limit
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Strain Life Curve / Crack Precursor Size
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Strain Crystallization Effects
Nonrelaxing Option
Quantify Strain
Crystallization, Min and
Mean Strain Effects
1.E-03
R=0
Energy Release Rate T
T
Tmax 1.E-07
Tmin 1.E-08
R Tmin
Tmax 1.E-09
1.E-10
Time x
1.E-11
1.E+01 1.E+02 1.E+03 1.E+04
Peak Driving Force, J/m^2
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GM – Analysis of Bushing Under Road Loads
4000
Fx, N 2000
-2000
0 200 400 600 800 1000 1200 1400
500
Fy, N 0
-500
0 200 400 600 800 1000 1200 1400
5000
Fz, N 0
-5000
0 200 400 600 800 1000 1200 1400
Barbash, Kevin P., and William V. Mars. Critical Plane Analysis of Rubber
Bushing Durability under Road Loads. No. 2016-01-0393. SAE Technical
Paper, 2016.
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Material Characterization
4
Observations
c0=0.0123 mm
c0=0.008 mm
c0=0.020 mm
2
Engineering Strain
1
0.5
1.E+03 1.E+04 1.E+05 1.E+06
Fatigue Life, cycles
Stress-Strain Curve Fit Crack Growth Curve Fit Crack Precursor Size Fit
1
1.5 8
0.9
2
0.8 7
0.7
6
1
3
0.6
2
Strain Amplitude
2
5
x(R)
0.5 GC71_23C_FCG_nrF_6
3
GC71_23C_FCG_nrM_6
4
0.4 3 2
GC71_23C_FCG_nrL_6a 4
4 4
0.3
pick=1 0.5 3
2
5
5
5
0.2 3
4
3
6
0.1 5
6
6 6 2
0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
R ratio 0 1
-0.5 0 0.5 1 1.5
Haigh Diagram
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Failure modes for different road load cases
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Multi-axis FLCA Bush Validation
Test Inputs Radial Axial Torsional Radial & Torsional
Test Conditions +/- 7,000N +/- 2,000N +/- 43° +/- 4,500N & +/- 30°
Termination Conditions +/- 9.5 mm +/-22 mm 80,000 Cycles +/-7.75 mm Radial Travel
fe-safe/Rubber Cycles (1 mm Tear) 17,257 65,912 37,668 12,162
Cycle of Initial Rate Change 24,132 77,275 50,000 13,362
Part Rate Life vs Prediction 140% 117% 133% 110%
Bench Durability Cycles 28,142 83,685 79,195 21,374
Tear Length End of Test 14.32 mm 17.55 mm 23.57 mm 19.57 mm
Goossens, Joshua R., William Mars, Guy Smith, Paul Heil, Scott Braddock,
and Jeanette Pilarski. Durability Analysis of 3-Axis Input to Elastomeric
Front Lower Control Arm Vertical Ride Bushing. No. 2017-01-1857. SAE
Technical Paper, 2017.
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Fully relaxing vs. Nonrelaxing
R is the R-ratio
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Crack Orientation – Test vs. Analysis – 0%-100%
900 Fexp = 12
• Cracks appear to be distributed in random angles compared to other load cases. Failed
samples qualitatively look very different.
• Due to this random distribution of cracks this load case could be used to gauge
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strength of the strain crystallization effect (Fexp).
Crack Orientation – Test vs. Analysis – 50%-150%
170 Fexp = 12
TIRE.HFO
…
**HISTORY
HISTTYPE=6CNE3D
HISTPERIOD=0.1 ! sec
ROLLING, STRIDE=2098
HIST=1, MAT=APEX
(NE11,NE22,NE33,NE12,NE,23,NE13)
…
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Material Behavior: Crack growth rate law
1.E-02
GJ Lake, PB Lindley,
Rubber Journal, Vol
1.E-03 146, No 11, pp 30-
Crack Growth Rate, mm/cyc
39 1964.
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100% Nf ΔW
.24
.12
.25
.12
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Crack Closure during Tire Rolling
Mars, W. V., Wei Y.T., Wang, H., Bauman, M. (2017). Computing Tire Component
Durability via Critical Plane Analysis, Tire Science and Technology, 45 (in press).
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Thermal Effects
Cycles to 1 mm Crack
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Tire Loading History
• FMVSS 139 schedule
• 85% load – 4 hrs. at 75 mph
• 90% load – 6 hrs. at 75 mph
• 100% load – 24 hrs. at 75 mph
• Additional Loads after running FMVSS
• Increasing loads were applied after completing the FMVSS schedule to
examine the effect on the fatigue life.
• Loads at 110%, 125%, 150%, and 200% were applied for 24 hrs. at 75mph.
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Analysis workflow Finite Element
Analysis
.hfi Initial
Damage State
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Fatigue Life Remaining after Damaging Event
Damaging overload
applied prior to 100% load
139,000
miles life
64,000
miles life
Tire fatigue life at 100% load with 100
miles of history at 200% load and 5
degree turn applied prior to 100% load.
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Forward Paths…
Analyze Durability of
Learn More about Characterize
your Finite Element
Principles and Practices Your Material
Model
Test My
Material!
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