Search Results

Fatigue life predictions using the strain-life method are used in the design of modern light weight vehicle, for the complex loading that occur with the structural durability tests that these vehicles undergo. The accuracy of these predictions is dependent upon the many factors; geometry, loads & materials etc. This paper details a new procedure to ensure the quality and accuracy of the material parameters for the fatigue life prediction software. The material parameters for the solver are obtained by performing strain-controlled fatigue tests. The geometry of the coupons tested is determined by size and thickness of the material specimen that they are machined from and the loading regime in the test. Detailed data analyzed is conducted on these tests and the parameters that are used as input into the CAE strain-life fatigue prediction software are generated.

The paper examines the application of hydroforms to body structure design and presents application concepts for such formed components. The examination of a complete body structure employing a number of hydroforms both in the underframe and upper glass-house structure provides new learning for future applications. The Land Rover Freelander forms the basis for the comparison. A pre-development project resulted in the design, engineering and building of body structures incorporating a number of hydroformed components as an integral theme (Figure 1). The project scope included mass reduction whilst maintaining performance targets and attributes. The project identified issues for product design and the processing of components.