CAE Fatigue Analysis Projects

Report
Mahesh Software
Mahesh Software
Data Acquisition and Analysis Projects …
Customer
Commercial Truck Manufacturer (MNC)
Data Acquisition Summary
•110 channels strain,
acceleration
•Different kinds of roads (NH,
SH, coarse, rough, pot holed)
•Tracks
Deliverables
•Fatigue Life computation for individual
load cases
•Equivalent fatigue cycles for 1 million km
run mix
Mahesh Software
Data Acquisition and Analysis Projects …
Customer
Construction Equipment Manufacturer
(MNC)
Data Acquisition Summary
Deliverables
•500 channels of strain
•Stress statistics for each load case
•122 load cases
•Max, min, mean SD, RMS
•Test split due to HW limitations
(channel counts)
Mahesh Software
Data Acquisition and Analysis Projects …
Customer
Engineering Design Consultant(MNC)
Data Acquisition Summary
•Bench marking a construction
equipment
•94 channels of strain,
acceleration, load cell,
displacement transducer
•125 tests
Deliverables
•Stress statistics for each load case
•Max, min, mean SD, RMS
Mahesh Software
Data Acquisition and Analysis Projects …
Customer
Axles Manufacturer
Data Acquisition Summary
•32 channels strain
•2000 km road load data
•National Highway, State
highway, Kutcha Road …
Deliverables
•Stress statistics for each different type of
road
•Rainflow matrices
•Fatigue Life
Mahesh Software
Data Acquisition and Analysis Projects …
Customer
White Goods Manufacturer
Data Acquisition Summary
•32 channels strain
•Impact and Handling tests
•Packaging Assessment
Deliverables
•Stress statistics for each load case
•Plastic strain / residual strain values
Mahesh Software
Data Acquisition and Analysis Projects …
Customer
Wheel Rims Manufacturer
Data Acquisition Summary
•12 channels strain per wheel
• 7 different designs
•Measurement on test rigs
•Different inflation pressure
•Study effect of design
improvement
Deliverables
•Von Mises stress, Max Principal, Angle
Mahesh Software
Data Acquisition and Analysis Projects …
Customer
Passenger Vehicle Manufacturer (MNC)
Data Acquisition Summary
•Ride Comfort Measurement
• 24 ch triaxial accelerometers
•Measurement on various roads
•Benchmark tests
•Study ride comfort on new
vehicle for Indian roads
Deliverables
•Frequency Spectra for various roads
•Ride Comfort Indices (A(4), A(8), VDV,
VTV, rms …) as per ISO 2631
•Driver , Passenger (Front and Rear) seats
and floor pads
Mahesh Software
Data Acquisition and Analysis Projects …
Customer
Earth Moving Machinery Manufacturer
Data Acquisition Summary
•Cooling system trials
• 8 channel hydraulic pressure,
temperatures
•In house sign-off tests
Deliverables
•Cooling system performance values
•Temperature map across cooling sub
system
Mahesh Software
Data Acquisition and Analysis Projects …
Customer
Premier Automotive Research and
Certifying Agency
Data Acquisition Summary
•32 channels strain
• Impact tests
Deliverables
•Max stresses due to impact
•Residual plastic strain at critical locations
Mahesh Software
Data Acquisition and Analysis Projects …
Customer
Suspension Systems Manufacturer
Data Acquisition Summary
•Pre-load measurement on
assembly
• Review of manufacturing
practice
Deliverables
•Pre-load on outer tube
Mahesh Software
Data Acquisition and Analysis Projects …
Customer
Construction Equipment Manufacturer
Data Acquisition Summary
•32 channels of strain, load cell
•SAE load cases
•Stress at critical locations
during break out and max
digging force conditions
Deliverables
•Stress statistics for each load case
•Max, min, mean SD, RMS
•Von Mises, Max Principal
Mahesh Software
Data Acquisition and Analysis Projects …
Customer
Seat Manufacturer
Data Acquisition Summary
•6 channels of triaxial
acceleration on seat and
platform
•Test in mines
•Heavy Earthmoving Machines
•Field Tests
Deliverables
•Ride Comfort Indices
•Data reduction for accelerated laboratory
simulation
•Random Vibration Simulation
specifications for lab tests
Mahesh Software
Data Acquisition and Analysis Projects …
Customer
Construction Equipment Manufacturer
Data Acquisition Summary
Deliverables
•96 channels of strain, cylinder
displacement
•Real World Usage Pattern tests
•Stress at critical locations
•New design evaluation
•Stress statistics for each load case
•Max, min, mean SD, RMS
•Von Mises, Max Principal
•Fatigue life of critical structures
•Sensitivity studies for different usage “mix”
Mahesh Software
Data Acquisition and Analysis Projects …
Customer
Construction Equipment Manufacturer
Data Acquisition Summary
•48 channels of strain,
acceleration
•Torture Track test evaluation
•Stresses at critical locations
•Sign-off tests before mass
production
Deliverables
•Stress statistics for each load case
•Max, min, mean SD, RMS
•Von Mises, Max Principal
•Fatigue life at critical locations
Mahesh Software
Data Acquisition and Analysis Projects …
Customer
Rail Coach Manufacturer
Data Acquisition Summary
•110 channels of strain
•Test Rig measurement
•Various test setups (loading
directions)
•New design + proto evaluation
Deliverables
•Stress statistics for each load case
•Max, min, mean SD, RMS
•Von Mises, Max Principal, direction …
Mahesh Software
Data Acquisition and Analysis Projects …
Customer
Construction Equipment Manufacturer
Data Acquisition Summary
•32 channels of strain
•Stresses at critical locations
•SAE load cases
•Breakout force, max digging
force load cases
•New design evaluation
Deliverables
•Stress statistics for each load case
•Max, min, mean SD, RMS
•Von Mises, Max Principal
Mahesh Software
Data Acquisition and Analysis Projects …
Customer
Construction Equipment Manufacturer
Data Acquisition Summary
•40channels of strain
•Stresses at critical locations
•Real world usage load cases
•New design evaluation
Deliverables
•Stress statistics for each load case
•Max, min, mean SD, RMS
•Von Mises, Max Principal
Mahesh Software
Data Acquisition and Analysis Projects …
Customer
Diesel Engine Manufacturer (MNC)
Data Acquisition Summary
•Residual strain measurement
•Cylinder head and block
castings
•Evaluate casting process
Deliverables
•Residual stresses at various critical
locations
Mahesh Software
Data Acquisition and Analysis Projects …
Customer
Agricultural Tractor Manufacturer (MNC)
Data Acquisition Summary
•32 channels strain
measurement
•Torture track
•Evaluate critical structures in
process of indigenisation
Deliverables
•Stresses at various critical locations
Mahesh Software
Data Acquisition and Analysis Projects …
Customer
Automotive (MNC)
Data Acquisition Summary
•Alloy Wheel
•27 channels strain
measurement
•Test Rig
•Steady state and impact
•Evaluate stresses in critical
regions
Deliverables
•Stresses at various critical locations
•Von Mises, Max Principal, Direction
•Impact test analysis
•Residual plastic strain
Mahesh Software
Data Acquisition and Analysis Projects …
Customer
White Goods Manufacturer
Data Acquisition Summary
•24 channels strain +
acceleration
•Lab Durability Tests
•24x7 acquisition over 40 days
Deliverables
•Stress pattern at critical failure prone
zones
•Evaluation of stress pattern w.r.t testing
time
•Measure “de-gradation”
•Inputs for MBD simulation for correlation
Mahesh Software
Data Acquisition and Analysis Projects …
Customer
Seat Manufacturer
Data Acquisition Summary
•6 channels of triaxial
acceleration on seat and
platform
•Torture Test Track
•Construction Machine
Deliverables
•Ride Comfort Indices
•Data reduction for accelerated laboratory
simulation
•Random Vibration Simulation
specifications for lab tests
Mahesh Software
Data Analysis Projects …
Customer
Engine Air Cleaner Manufacturer
Data Acquisition Summary
•Test data provided by customer
•Triaxial Acceleration Data on
air cleaner mounts under
various engine events / cycles
Deliverables
•Data reduction and Test Program for an
accelerated ED Shaker Test
•Random Vibration Simulation
specifications for accelerated lab tests
Mahesh Software
Data Analysis Projects …
Customer
Tractor Manufacturer
Data Acquisition Summary
•Test data provided by customer
•Accelerations, strains, torques,
shaft speeds for various
operating events / cycles
•200+ events
•Many Duty Cycles
Deliverables
•Data reduction to understand product
performance
•Generation of Design Data --- max
powertrain loads, efficiencies …
Mahesh Software
Mahesh Software
CAE Fatigue Analysis Projects …
Customer
CAE Consultant
Data Acquisition Summary
•Pressure Vessel Head
•Different pressure load cases
•Concentration around the
connections
Deliverables
•Fatigue Life and Hot Spots evaluation
•Evaluate with different materials
Mahesh Software
CAE Fatigue Analysis Projects …
Customer
CAE Consultant
Data Acquisition Summary
•Cast Iron Pulley
•Heavily loaded in a conveyer
belt system
•Concentration around the
central bore
•Review of different design
modifications
Deliverables
•Fatigue Life and Hot Spots evaluation
Mahesh Software
CAE Fatigue Analysis Projects …
Customer
CAE Consultant
Data Acquisition Summary
•Air Cleaner Bracket Mounting
•Vibration Fatigue Evaluation
•Input PSD known from RLD
•3 load cases (X,Y,Z)
Deliverables
•Fatigue Life and Hot Spots evaluation
Mahesh Software
Mahesh Software
Consultancy Projects …
Customer
Project
Major Tractor Manufacturer
Structural Durability Validation of complete tractor
assembly
Consultancy Activities Summary
•Structural Durability Process forming and finalisation
•Supervise strain gaging of critical structural members
•Plan and Supervise tractor data acquisition
•Evolve Data Analysis procedures
•Duty cycle generation
•Arriving at an accelerated laboratory test program (Load Blocks)
•Advise related to test rig construction
Mahesh Software
Consultancy Projects …
Customer
Project
Major Tractor Manufacturer
Complete Tractor Powertrain Durability Validation
Consultancy Activities Summary
•Durability Process evolving
•Plan and Supervise tractor data acquisition
•Powertrain mapping
•Duty cycle generation
•Arriving at an accelerated laboratory test program (Transmission Load
Blocks)
Mahesh Software

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