OEMs increase the pressure on their suppliers to design, develop and test their products within a short time period. This requires design first-time-right philosophy and advanced numerical and experimental methods. Four steps are required to experimentally asses the durability of exhaust systems. Environmental loads and strain references are acquired on the test track. This data is analyzed and damaging sections are retained. These sections are then reproduced on a test rig. During this reproduction, strain is measured at the reference locations and the damage is calculated and compared with the original test track data. On the hydraulic test rig, the acceleration targets are reproduced with high accuracy, but some of the horizontal plane bending strain targets are not well reproduced due to the absence of lateral degrees of freedom in the engine simulator and the bracket actuators. The results from the experiments are then compared with numerical fatigue simulations to develop and improve Thermo-Mechanical Fatigue (TMF) models. Accurate test results therefore contribute significantly to the development of lightweight exhaust systems through virtual prototyping. It is shown that a good damage correlation is already achieved for the vertical plane, but more work is needed to include lateral road load data.
Multi-axial road load reproductions for the durability assessment of lightweight stainless steel exhaust systems
2009
9 Seiten, 7 Bilder, 10 Quellen
Conference paper
English
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