2008 Int ANSYS Conf Trailer Hitch System

2008 International ANSYS Conference
Fatigue analysis and design optimization of a trailer hitch system

Erke Wang, Rainer Rauch CADFEM GmbH Germany
2008 ANSYS, Inc. All rights reserved.
ANSYS, Inc. Proprietary

Content Description of customer needs Some remarks on the fatigue assessment of welded parts Workbench work flow to analyze welded structures Fatigue analysis and comparison to test results Return on Invest DXplorer study based on parameterized DM-model Summary
Fatigue analysis and design optimization of a trailer hitch system Customer needs
Every part has to pass a fatigue test with 2.E6 cycles Testing time approximately 4 days Increased complexity of component removable trailer hitch Increased loading due to increasing performance of towing vehicle (SUV)
Tests facility
Location of failure
3
Fatigue analysis and design optimization of a trailer hitch system German SUVs
Porsche Cayenne 368 kW (500 HP)
Audi Q7 368 kW (500 HP)
VW Touareg 850 Nm
BMW X6 300 kW (407 HP)

4

Stress in welded structures
What stress component can we use as a reference? Geometry of weld cannot be modeled in detail Material properties vary over weld cross section Measure and calculate stresses at locations adjacent to the weld define reference weld geometries

Approaches to assess welded structures welded structures
During the product development cycle, the following approaches are widely used to assess the welded structures life cycle, depending on the nature of the problem, the appreciated approach will be used. Nominal stress approach Structural hot spot stress approach Notch stress approach Linear elastic fracture mechanics Not valid for the approval of automotive components

Nominal stress approach:
S= F / A
Way too conservative useful for structures like cranes
Structural hot spot approach: Measure and calculate stresses at locations adjacent to the weld Notch stress approach: define reference weld geometries
SREF = DS * Ds

Structural hot spot approach: stresses can be calculated using shell or solid elements According to the design detail, there are N of welded details in catalogue available (IIW-Recommendations), which describe where the stress could be measured.
Comparison of allowable stress component for welded detail


Approaches to assess welded structures:
FAT 63 63 MPa
According to the catalogue, one reference SN curve can be chosen to compare with calculated stress results.

There are several approaches to assess welded structures Nominal stress approach Structural hot spot stress approach Notch stress approach Linear elastic fracture mechanics
Not valid for the approval of automotive components Way too conservative useful for structures like cranes N of welded details in catalogue (IIW-Recommendations) is limited
10

Notch stress approach R1MS - Radius 1 Max Stress (acc. to IIW-Recommendations)
IIW-Recommendations FE Model
Geometric detail of the weld seam Radius=1mm
Pros and Cons: + concept for suitable for the FE-process + no structural detail list necessary + straightforward in result interpretation - high number of elements
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Notch stress approach
IIW-Recommendations FE Model
Geometric detail of the weld seam Accuracy With this approach, the FE model must be modeled in weld region with very fine mesh, this leaded to a very large FE model. Because of the hardware performance and software efficiency issues, this approach was not widely used in product development process
Fatigue assessment of a welded component in a construction machinery based on different methods J. Martinsson, J. Samuelsson IIW DOCUMENT No. XIII-1905-01
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Notch stress approach an economic way based on ANSYS Workbench technology
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A short revive on the submodel - technique 2.
1.
Physical Model Global model Submodel
1. Generate Submodel (Design Modeler!) 2. Transfer Displacements as Boundary Conditions on Submodel
14

Submodel examples
Global model without welded detail Shell element Local model 1
Local model 2
Global model
Submodel with welded detail Solid element
Local model 3
15

Submodel examples
Submodel Submodel with different mesh
Global model
16
Fatigue analysis and design optimization of a trailer hitch system Work flow
1. 2. 3. 4. 5. Analyze global structure using a uniform element size Identify hot spots Prepare Submodel -geometry feasible for the R1MS-assessment Calculate local results with different Submodels Use Workbench Fatigue for Life time estimation
17

(1) Analyze global model (2) identify potentially critical location
critical location
/copy,file,rst,,..\voll,rst save,file,db /copy, file,db,,..\voll,db
18

(3) Prepare Submodel(s) acc. to IIW-Recommendations
/prep7 cmsel,s,CUT nwrite,cut,node alls save fini /clear /post1 resu,..\voll,db /post1 file,..\voll,rst set,last alls cbdo,cut,node,,cbdo,cbdo fini resu /prep7 /inp,cbdo,cbdo alls /solu
19

Check results for all defined submodels
Model 1 Test 1 Test 2 N of cycles estimated 600.000 600.000 N of cycles estimated 870.000 870.000 N of cycles estimated > 2 Mill. > 2 Mill. N of cycles in test 790.000 880.000 N of cycles in test 1.3 Mill. 1.1 Mill. N of cycles in test @ 2 Mill. test stop 1.75 Mill.
Model 2 Test 1 Test 2
Model 3 Test 1 Test 2
20

Reviewing results with ANSYS Fatigue (Model 1)
log [MPa]
225
Estimated life at maximum load amplitude (realistic test scenario?)

2E6
log [N]
21

Reviewing results with ANSYS Fatigue
log [MPa]
225
Estimated life at a varying load amplitude (more realistic test scenario)

2E6
log [N]
22
ROI for the analyzed structures
23
Fatigue analysis and design optimization of a trailer hitch system Do the simulations pay off?
Cost for prototype: Test rig 3 days: Preparation/Docu: Cost per test: TECS Professional: Engineer: Cost per year: 400 1.200.- Euro 2.500.- Euro 500.- Euro 3.400 4.200.- Euro 4.100.- Euro 60.000.- Euro 64.100.- Euro
Preventing 16 unsucessful tests each year pays off all cost for simulation!
24
Fatigue analysis and design optimization of a trailer hitch system Do the simulations pay off?
Time to analyze a complete trailer hitch system: 1 5 days
Uncounted numbers: - Costs for re-design (CAD, PDM, Customer discussions) - Delay in project - Reputation and acknowledge technical know how - Knowledge about the product
25
Knowledge about the product or how to optimize products
26

Parameterize geometry generate dependent parameters to guarantee feasible models during optimization run
27

Define Boundary Conditions and depedent parameters in welded detail
28

Check sensitivity of geometry parameters on loading of the critical welds
Check all relevant stresses and displacements
Review sensitivities
Select pipe diameter and wall thickness (integers)

29
Simulation as applied Science to replace the try-and-error process Extended product knowledge
Freeze design by direct use of simulation results
DXplorer Simulation Driven Design
30
Fatigue analysis and design optimization of a trailer hitch system Summary

ANSYS Workbench delivers the possibility to assess Accuracy even complicated welded details with local models. The submodel approach is extremely efficient all documentation is done via the structured tree. ANSYS Fatigue Module provides the opportunity to account for fatigue effects like mean stresses and load history. With the ANSYS DesignXplorer design decisions are based on knowledge not on presumptions.
31
Thanks!
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2008 Int ANSYS Conf Trailer Hitch System

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2008 International ANSYS Conference

Fatigue analysis and design optimization of a trailer hitch system

ANSYS, Inc. Proprietary

Fatigue analysis and design optimization of a trailer hitch system

2008 ANSYS, Inc. All rights reserved.

ANSYS, Inc. Proprietary

Porsche Cayenne 368 kW (500 HP)

Audi Q7 368 kW (500 HP)

BMW X6 300 kW (407 HP)

Fatigue analysis and design optimization of a trailer hitch system

2008 ANSYS, Inc. All rights reserved.

ANSYS, Inc. Proprietary

Fatigue analysis and design optimization of a trailer hitch system

2008 ANSYS, Inc. All rights reserved.

ANSYS, Inc. Proprietary

Fatigue analysis and design optimization of a trailer hitch system

Way too conservative useful for structures like cranes

2008 ANSYS, Inc. All rights reserved.

ANSYS, Inc. Proprietary

Fatigue analysis and design optimization of a trailer hitch system

Comparison of allowable stress component for welded detail

ANSYS, Inc. Proprietary

Fatigue analysis and design optimization of a trailer hitch system

2008 ANSYS, Inc. All rights reserved.

ANSYS, Inc. Proprietary

Fatigue analysis and design optimization of a trailer hitch system

2008 ANSYS, Inc. All rights reserved.

ANSYS, Inc. Proprietary

Fatigue analysis and design optimization of a trailer hitch system

Geometric detail of the weld seam Radius=1mm

2008 ANSYS, Inc. All rights reserved.

ANSYS, Inc. Proprietary

Fatigue analysis and design optimization of a trailer hitch system

ANSYS, Inc. Proprietary

Fatigue analysis and design optimization of a trailer hitch system

Notch stress approach an economic way based on ANSYS Workbench technology

2008 ANSYS, Inc. All rights reserved.

ANSYS, Inc. Proprietary

Fatigue analysis and design optimization of a trailer hitch system

1. Generate Submodel (Design Modeler!) 2. Transfer Displacements as Boundary Conditions on Submodel

2008 ANSYS, Inc. All rights reserved.

ANSYS, Inc. Proprietary

Fatigue analysis and design optimization of a trailer hitch system

Submodel with welded detail Solid element

2008 ANSYS, Inc. All rights reserved.

ANSYS, Inc. Proprietary

Fatigue analysis and design optimization of a trailer hitch system

ANSYS, Inc. Proprietary

2008 ANSYS, Inc. All rights reserved.

ANSYS, Inc. Proprietary

Fatigue analysis and design optimization of a trailer hitch system

/copy,file,rst,,..\voll,rst save,file,db /copy, file,db,,..\voll,db

2008 ANSYS, Inc. All rights reserved.

ANSYS, Inc. Proprietary

Fatigue analysis and design optimization of a trailer hitch system

ANSYS, Inc. Proprietary

Fatigue analysis and design optimization of a trailer hitch system

Model 2 Test 1 Test 2

Model 3 Test 1 Test 2

2008 ANSYS, Inc. All rights reserved.

ANSYS, Inc. Proprietary

Fatigue analysis and design optimization of a trailer hitch system

Estimated life at maximum load amplitude (realistic test scenario?)