Automotive bulb shield is an important stamping component in automotive lighting system and vibration durability is a critical performance requirement. In this study, a Finite Element (FE) based method to model the vibration phenomenon and to predict fatigue life is introduced. In this method, the vibration phenomenon is modelled by dynamic explicit FEM simulation and the calculated stress history is extracted to calculate fatigue life by stress based method. The method is demonstrated on a bulb shield made for a northern American model vehicle. SAE575 test standard for automotive lighting system is modelled. The predicted fatigue life is only 9% away from the test measurement. The FE based method also points out the fatigue performance improve on a tailor-welded design. The investigated bulb shields are progressive forming from tailor-welded strips, which are produced from a continuous welding laser welding configuration. Vibration test proves the tailor-welded design has gained up to 3 times fatigue life improvement.
Automotive bulb shield vibration durability prediction and tailor-welded improvement
2009
6 Seiten, 5 Bilder, 3 Tabellen, 7 Quellen
Conference paper
Storage medium
English
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