This paper shows a virtual durability product development process to predict the life of a short fiber-reinforced component of a passenger car. In the development of modern cars more and more traditional metal materials are substituted with short fiber-reinforced polymers. The advantage of short fiber-reinforced polymers is the combination of lower weight with adequate strength. A fatigue life prediction of these materials gives fundamental direction for the development of components at an early stage. Starting point is a flow simulation of fiber orientation in the production process, followed by a structural analysis and finished by a fatigue calculation. A multi-body dynamic system (MBS) is used for the simulation of a physical durability component test to generate loads. The virtual product development results in a correlation between lifetime prediction results and physical fatigue failures, which occurred during an endurance test of a prototype on the proving ground. The virtual durability product development process helps to indicate weakness or critical locations of the design at the early state in the concept phase. By adopting 'virtual testing', an approach that integrates physical testing with analytical procedures through integrated durability product development, manufacturers can develop more efficient and cost-effective ways of ensuring product durability. The payoff is substantial. The fatigue simulation shows very good correlation to the critical locations. An optimized fatigue simulation gives additional model information, which is previously not available, gives more realistic results using fiber orientation material parameter compared to simple random material properties and illustrates the advantages of the design. The process combines standard software tools and is easy to integrate in existing CAE environments. It will save costly re-designs and re-tests Beside the information of structural analysis and MBS fatigue information based on fiber orientation dependent material properties gives new insight into material performance.
Fatigue of engineering polymers
Materialermüdung von Polymeren
2006
12 Seiten, 12 Bilder, 5 Quellen
Conference paper
English
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