Durability of Elastomeric Bushings Computed from Track-Recorded Multi-Channel Road Load Input 2024-01-2253

The qualification requirements of automakers derive from track testing in which road load and moment inputs to a part in x, y and z directions are recorded over a set of driving conditions selected to represent typical operation. Because recorded histories are lengthy, often comprising many millions of time steps, past industry practice has been to specify simplified block cycle schedules for purposes of durability testing or analysis. Simplification, however, depends on imprecise human judgement, and risks fidelity of the inferred life and failure mode relative to actual. Fortunately, virtual methods for fatigue life prediction are available that are capable of processing full, real-time, multiaxial road load histories. Two examples of filled natural rubber ride bushings are considered here to demonstrate. Each bushing is subject to a schedule of 11 distinct recorded track events. Endurica EIE^TM map building procedures are first used together with a finite element solution to map the 6 channel loading space and to obtain stress/strain solutions at each gridpoint in the load space. EIE is then used with the recorded histories to interpolate from the recorded road load inputs on the bushing to stress-strain history at each element centroid in the finite element model. The interpolated stress-strain histories are then used to compute damage accrual and fatigue life across all 11 events. The computational requirements of this workflow are benchmarked with the outcome that the entire schedule in full detail can be analyzed on a timescale well suited for use at the earliest stages of business development and engineering.