CAE Fatigue Analysis Projects
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Mahesh Software Mahesh Software Data Acquisition and Analysis Projects … Customer Commercial Truck Manufacturer (MNC) Data Acquisition Summary •110 channels strain, acceleration •Different kinds of roads (NH, SH, coarse, rough, pot holed) •Tracks Deliverables •Fatigue Life computation for individual load cases •Equivalent fatigue cycles for 1 million km run mix Mahesh Software Data Acquisition and Analysis Projects … Customer Construction Equipment Manufacturer (MNC) Data Acquisition Summary Deliverables •500 channels of strain •Stress statistics for each load case •122 load cases •Max, min, mean SD, RMS •Test split due to HW limitations (channel counts) Mahesh Software Data Acquisition and Analysis Projects … Customer Engineering Design Consultant(MNC) Data Acquisition Summary •Bench marking a construction equipment •94 channels of strain, acceleration, load cell, displacement transducer •125 tests Deliverables •Stress statistics for each load case •Max, min, mean SD, RMS Mahesh Software Data Acquisition and Analysis Projects … Customer Axles Manufacturer Data Acquisition Summary •32 channels strain •2000 km road load data •National Highway, State highway, Kutcha Road … Deliverables •Stress statistics for each different type of road •Rainflow matrices •Fatigue Life Mahesh Software Data Acquisition and Analysis Projects … Customer White Goods Manufacturer Data Acquisition Summary •32 channels strain •Impact and Handling tests •Packaging Assessment Deliverables •Stress statistics for each load case •Plastic strain / residual strain values Mahesh Software Data Acquisition and Analysis Projects … Customer Wheel Rims Manufacturer Data Acquisition Summary •12 channels strain per wheel • 7 different designs •Measurement on test rigs •Different inflation pressure •Study effect of design improvement Deliverables •Von Mises stress, Max Principal, Angle Mahesh Software Data Acquisition and Analysis Projects … Customer Passenger Vehicle Manufacturer (MNC) Data Acquisition Summary •Ride Comfort Measurement • 24 ch triaxial accelerometers •Measurement on various roads •Benchmark tests •Study ride comfort on new vehicle for Indian roads Deliverables •Frequency Spectra for various roads •Ride Comfort Indices (A(4), A(8), VDV, VTV, rms …) as per ISO 2631 •Driver , Passenger (Front and Rear) seats and floor pads Mahesh Software Data Acquisition and Analysis Projects … Customer Earth Moving Machinery Manufacturer Data Acquisition Summary •Cooling system trials • 8 channel hydraulic pressure, temperatures •In house sign-off tests Deliverables •Cooling system performance values •Temperature map across cooling sub system Mahesh Software Data Acquisition and Analysis Projects … Customer Premier Automotive Research and Certifying Agency Data Acquisition Summary •32 channels strain • Impact tests Deliverables •Max stresses due to impact •Residual plastic strain at critical locations Mahesh Software Data Acquisition and Analysis Projects … Customer Suspension Systems Manufacturer Data Acquisition Summary •Pre-load measurement on assembly • Review of manufacturing practice Deliverables •Pre-load on outer tube Mahesh Software Data Acquisition and Analysis Projects … Customer Construction Equipment Manufacturer Data Acquisition Summary •32 channels of strain, load cell •SAE load cases •Stress at critical locations during break out and max digging force conditions Deliverables •Stress statistics for each load case •Max, min, mean SD, RMS •Von Mises, Max Principal Mahesh Software Data Acquisition and Analysis Projects … Customer Seat Manufacturer Data Acquisition Summary •6 channels of triaxial acceleration on seat and platform •Test in mines •Heavy Earthmoving Machines •Field Tests Deliverables •Ride Comfort Indices •Data reduction for accelerated laboratory simulation •Random Vibration Simulation specifications for lab tests Mahesh Software Data Acquisition and Analysis Projects … Customer Construction Equipment Manufacturer Data Acquisition Summary Deliverables •96 channels of strain, cylinder displacement •Real World Usage Pattern tests •Stress at critical locations •New design evaluation •Stress statistics for each load case •Max, min, mean SD, RMS •Von Mises, Max Principal •Fatigue life of critical structures •Sensitivity studies for different usage “mix” Mahesh Software Data Acquisition and Analysis Projects … Customer Construction Equipment Manufacturer Data Acquisition Summary •48 channels of strain, acceleration •Torture Track test evaluation •Stresses at critical locations •Sign-off tests before mass production Deliverables •Stress statistics for each load case •Max, min, mean SD, RMS •Von Mises, Max Principal •Fatigue life at critical locations Mahesh Software Data Acquisition and Analysis Projects … Customer Rail Coach Manufacturer Data Acquisition Summary •110 channels of strain •Test Rig measurement •Various test setups (loading directions) •New design + proto evaluation Deliverables •Stress statistics for each load case •Max, min, mean SD, RMS •Von Mises, Max Principal, direction … Mahesh Software Data Acquisition and Analysis Projects … Customer Construction Equipment Manufacturer Data Acquisition Summary •32 channels of strain •Stresses at critical locations •SAE load cases •Breakout force, max digging force load cases •New design evaluation Deliverables •Stress statistics for each load case •Max, min, mean SD, RMS •Von Mises, Max Principal Mahesh Software Data Acquisition and Analysis Projects … Customer Construction Equipment Manufacturer Data Acquisition Summary •40channels of strain •Stresses at critical locations •Real world usage load cases •New design evaluation Deliverables •Stress statistics for each load case •Max, min, mean SD, RMS •Von Mises, Max Principal Mahesh Software Data Acquisition and Analysis Projects … Customer Diesel Engine Manufacturer (MNC) Data Acquisition Summary •Residual strain measurement •Cylinder head and block castings •Evaluate casting process Deliverables •Residual stresses at various critical locations Mahesh Software Data Acquisition and Analysis Projects … Customer Agricultural Tractor Manufacturer (MNC) Data Acquisition Summary •32 channels strain measurement •Torture track •Evaluate critical structures in process of indigenisation Deliverables •Stresses at various critical locations Mahesh Software Data Acquisition and Analysis Projects … Customer Automotive (MNC) Data Acquisition Summary •Alloy Wheel •27 channels strain measurement •Test Rig •Steady state and impact •Evaluate stresses in critical regions Deliverables •Stresses at various critical locations •Von Mises, Max Principal, Direction •Impact test analysis •Residual plastic strain Mahesh Software Data Acquisition and Analysis Projects … Customer White Goods Manufacturer Data Acquisition Summary •24 channels strain + acceleration •Lab Durability Tests •24x7 acquisition over 40 days Deliverables •Stress pattern at critical failure prone zones •Evaluation of stress pattern w.r.t testing time •Measure “de-gradation” •Inputs for MBD simulation for correlation Mahesh Software Data Acquisition and Analysis Projects … Customer Seat Manufacturer Data Acquisition Summary •6 channels of triaxial acceleration on seat and platform •Torture Test Track •Construction Machine Deliverables •Ride Comfort Indices •Data reduction for accelerated laboratory simulation •Random Vibration Simulation specifications for lab tests Mahesh Software Data Analysis Projects … Customer Engine Air Cleaner Manufacturer Data Acquisition Summary •Test data provided by customer •Triaxial Acceleration Data on air cleaner mounts under various engine events / cycles Deliverables •Data reduction and Test Program for an accelerated ED Shaker Test •Random Vibration Simulation specifications for accelerated lab tests Mahesh Software Data Analysis Projects … Customer Tractor Manufacturer Data Acquisition Summary •Test data provided by customer •Accelerations, strains, torques, shaft speeds for various operating events / cycles •200+ events •Many Duty Cycles Deliverables •Data reduction to understand product performance •Generation of Design Data --- max powertrain loads, efficiencies … Mahesh Software Mahesh Software CAE Fatigue Analysis Projects … Customer CAE Consultant Data Acquisition Summary •Pressure Vessel Head •Different pressure load cases •Concentration around the connections Deliverables •Fatigue Life and Hot Spots evaluation •Evaluate with different materials Mahesh Software CAE Fatigue Analysis Projects … Customer CAE Consultant Data Acquisition Summary •Cast Iron Pulley •Heavily loaded in a conveyer belt system •Concentration around the central bore •Review of different design modifications Deliverables •Fatigue Life and Hot Spots evaluation Mahesh Software CAE Fatigue Analysis Projects … Customer CAE Consultant Data Acquisition Summary •Air Cleaner Bracket Mounting •Vibration Fatigue Evaluation •Input PSD known from RLD •3 load cases (X,Y,Z) Deliverables •Fatigue Life and Hot Spots evaluation Mahesh Software Mahesh Software Consultancy Projects … Customer Project Major Tractor Manufacturer Structural Durability Validation of complete tractor assembly Consultancy Activities Summary •Structural Durability Process forming and finalisation •Supervise strain gaging of critical structural members •Plan and Supervise tractor data acquisition •Evolve Data Analysis procedures •Duty cycle generation •Arriving at an accelerated laboratory test program (Load Blocks) •Advise related to test rig construction Mahesh Software Consultancy Projects … Customer Project Major Tractor Manufacturer Complete Tractor Powertrain Durability Validation Consultancy Activities Summary •Durability Process evolving •Plan and Supervise tractor data acquisition •Powertrain mapping •Duty cycle generation •Arriving at an accelerated laboratory test program (Transmission Load Blocks) Mahesh Software
