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首页> 外文会议>Symposium on International Automotive Technology >FEA Based Durability Evaluation of HD Tipper Chassis and Cab Through Correlated Transient and Fatigue Analysis
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FEA Based Durability Evaluation of HD Tipper Chassis and Cab Through Correlated Transient and Fatigue Analysis

机译：通过相关的瞬态和疲劳分析，基于FEA的高清倾斜底盘和驾驶室的耐久性评估

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Durability evaluation and Fatigue Life estimation for commercial vehicle Chassis and Cab is an important milestone during product design and development. Commonly used methods like endurance testing of vehicles on field, accelerated testing on four-posters or test tracks are time consuming and costly. On the other hand, virtual methods for durability evaluation give useful information early in design cycle and save considerable time and cost. They give flexibility to evaluate multiple design options and accommodate design changes early in product development cycle. Virtual testing methods commonly used in industry for durability evaluation of truck Chassis and Cab are combination of Multi-body Simulation (in software like Adams) and Fatigue Life estimation (in software like FEMFAT). These MBS models for truck are rigid or partly flexible and the simulation run-time increases drastically with increase in number of flexible parts in model. Vehicle suspensions are modelled mostly as rigid mechanisms with appropriate stiffness at the joints. Transient simulations done through MBS methods are mostly short duration with four-poster or six poster inputs. Dynamic correlation between test and simulation for these MBS methods are about 70-80%. Modal stresses and modal coordinates from MBS simulations are given as input to the fatigue solver for life estimation. Low level of dynamic correlation has manifold effect on accuracy of life estimates [1]. A different approach has been developed in VECV for durability evaluation of Truck Chassis and Cab, entirely through Finite Element Analysis route. This FEA approach has the biggest advantage of keeping entire model as flexible. Full flexibility in the model greatly improves the capture of Chassis, Suspension and Cab modes and helps in achieving improved dynamic correlation. Forces or accelerations as measured from test data acquisition in mines and test tracks are given as inputs to the Finite Element model of vehicle for transient analysis in Nastran. Nowadays, high performance compute servers make it quite convenient to run these FEA based transient analysis for a time period of 100-150 seconds with small time-steps. Smaller time-steps and full flexibility of the model enable high dynamic correlation between test and simulation in range of 85-95%. Stress vs. time output from the transient analysis in Nastran and fatigue material properties are given as input to fatigue solver FEMFAT which gives the life estimates for the Chassis and Cab. Since the stress vs. time history in this FEA based approach is for reasonably long duration, like 100-150 seconds, approximations in fatigue analysis are reduced and better estimates of life are obtained [2]. VE Commercial Vehicles is one of the leading commercial vehicle manufacturer in India with presence in both truck and bus segments. This paper will discuss the above described FEA based methodology for durability evaluation of a Heavy Duty Tipper Chassis and Cab through correlated transient and fatigue analysis. Service load data was acquired on Tipper in Mines, Construction Sites and Test Tracks and is used for transient analysis in Nastran. The FEA model is correlated for displacements and strains in time as well as frequency domain with the measured test data. Nastran stress vs. time results are used for fatigue life estimation in FEMFAT. Correlation is also done for damage calculated from test data and FEA results. High level of dynamic and fatigue correlations between test and simulation were obtained for Tipper Chassis and Cab. This FEA based durability evaluation methodology will help VECV in design of Chassis and Cab and their life prediction, early in product development cycle for all future projects.
机译：商用车底盘和驾驶室的耐久性评估和疲劳寿命估计是产品设计和开发期间的重要里程碑。通常使用的方法，如现场车辆的耐用性测试，在四海拔或测试轨道上加速测试是耗时和昂贵的。另一方面，用于耐久性评估的虚拟方法在设计周期提前提供有用的信息，并节省相当多的时间和成本。它们灵活地评估多种设计选项，并在产品开发周期早期适应设计变化。用于耐用性评价的虚拟测试方法卡车底盘和驾驶室的耐用性评估是多体仿真（亚当斯软件）和疲劳寿命估计（如Femfat的软件）的组合。这些用于卡车的MBS模型是刚性的或部分灵活的，并且模拟运行时间随着模型中的灵活部件数量的增加而增加。车辆悬浮液主要用作接头处具有适当刚度的刚性机构。通过MBS方法完成的瞬态仿真大多是四张海报或六个海报输入的短期。这些MBS方法的测试和仿真之间的动态相关性约为70-80％。 MBS模拟的模态应力和模态坐标作为终身估算的疲劳求解器的输入。低水平的动态相关性对寿命准确性的歧管效应估计[1]。在VECV中开发了一种不同的方法，以便于卡车底盘和驾驶室的耐用性评估，完全通过有限元分析路线。这种FEA方法具有保持整个模型作为灵活的最大优势。模型中的全部灵活性大大提高了底盘，悬架和驾驶室模式的捕获，并有助于实现改进的动态相关性。从测试数据采集中测量的力或加速度在地雷和测试轨道中被称为Nastran瞬态分析的车辆有限元模型的输入。如今，高性能计算服务器使得运行这些基于FEA的瞬态分析非常方便，时间步长为100-150秒的时间段。较小的时间步长和模型的全部灵活性使得测试和仿真之间的高动态相关性在85-95％之间。来自Nastran和疲劳材料特性的瞬态分析的应力与时间输出作为疲劳求解器Femfat的输入给出了底盘和驾驶室的寿命估计。由于压力与时间历史在该基于FEA的方法中是合理的持续时间，如100-150秒，因此减少了疲劳分析中的近似，并且获得了更好的寿命估计[2]。 VE商用车辆是印度领先的商业车辆制造商之一，在卡车和公共汽车段都存在。本文将通过相关的瞬态和疲劳分析讨论以上描述的基于FEA的基于FEA的方法。在矿山，施工站点和测试轨道中的Tipper上获取了服务负载数据，并用于Nastran的瞬态分析。 FEA模型与具有测量测试数据的时间的位移和菌株以及频域相关联。 Nastran压力与时间结果用于Femfat中的疲劳寿命估算。从测试数据和FEA结果计算的损坏也进行相关性。获得了试验和仿真之间的高水平动态和疲劳相关性，用于卸车底盘和驾驶室。这种基于FEA的耐久性评估方法将有助于VECV设计底盘和驾驶室以及他们未来项目的产品开发周期早期的寿命预测。

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