Low Cost Durability Virtual Verification Methodology 2011-26-0015

In the era of low cost product, enormous pressure to keep product development cost and time as low as possible. Durability verification and validation always consume big amount of product development cost and time. This paper gives low cost and quick, durability virtual verification which can be tested by running vehicle on track to check correlation.

In this low cost durability verification, maximum stress levels on Frame and Cabin are generated analytically at all hot spot location based on finite element inertia relief analysis. Basic input load data is acquired by running proto type vehicle on track. Mathematical loading spectrum (Range Vs Cycle-Cumulative frequency distribution) for track is evaluated from acquired data. Stress spectrums are generated analytically for all hot spot locations based on mathematical load spectrum. Analytically component S-N curve for frame, cabin components with different slops [1,2] is generated based on material ultimate tensile stress values. Damage is calculated for each hot spot locations using miner rule for durability targets like numbers of kilometers of track. Potential crack locations are identified on frame and cabin for durability target in verification. Testing results showed reasonable correlation with verification. As measurement of load data and fatigue material properties are not required, this method is cost effective, faster also reasonable accurate.