PSI - Issue 19

Available online at www.sciencedirect.com Available online at www.sciencedirect.com ScienceDirect Structural I t grity Procedia 00 (2019) 000–000 Available online at www.sciencedirect.com ScienceDirect Structural Integrity Procedia 00 (2019) 000–000

www.elsevier.com/locate/procedia www.elsevier.com/locate/procedia

ScienceDirect

Procedia Structural Integrity 19 (2019) 175–193

Fatigue Design 2019 Random vibration fatigue of welded structures - Applications in the automotive industry Giovanni M.Teixeira a , Martin Roberts a , Juliano Silva b Fatigue Design 2019 Random vibration fatigue of welded structures - Applications in the automotive industry Giovanni M.Teixeira a , Martin Roberts a , Juliano Silva b Abstract The automotive industry is facing its most significant transformation since the first Ford factory. The rise of electrical vehicles alongside autonomous driving and additive manufacturing increase demand for lightweight vehicles, which requires proper numerical analysis tools in place in order to keep the costs low and to achieve durability targets. Vibration in heavy and light-duty vehicles poses many challenges in the design phase mainly due to the uncertainties associated with the loads and material properties. Therefore stochastic methods have attracted the attention of engineers responsible for the fatigue assessment of truck chassis and their welded attachments. In order to address the mesh scale sensitivity in the finite element method (FEM), Dong et al created the Battelle Structural Stress Method, an elegant alternative to the Volvo nodal force/moment method which was named Verity®. For fatigue life evaluation of welds Verity® is used in conjunction with a master SN curve also developed by the same authors. The present paper proposes a frequency domain variant of the Verity® Method to be used in random vibration fatigue applications along with Dirlik and T&B methods. Frequency domain approaches enjoy the statistical advantage of using probability density functions instead of rainflow cycle counters, which offers computational benefits (in terms of time) in multi-channel long history scenarios. This paper thoroughly describes the proposal and shows an example of its application to a brake chamber support attached to the rear axle of a light-duty truck. Verity is used in the both the time and frequency domains and the fatigue results are compared. Abstract The automotive industry is facing its most significant transformation since the first Ford factory. The rise of electrical vehicles alongside autonomous driving and additive manufacturing increase demand for lightweight vehicles, which requires proper numerical analysis tools in place in order to keep the costs low and to achieve durability targets. Vibration in heavy and light-duty vehicles poses many challenges in the design phase mainly due to the uncertainties associated with the loads and material properties. Therefore stochastic methods have attracted the attention of engineers responsible for the fatigue assessment of truck chassis and their welded attachments. In order to address the mesh scale sensitivity in the finite element method (FEM), Dong et al created the Battelle Structural Stress Method, an elegant alternative to the Volvo nodal force/moment method which was named Verity®. For fatigue life evaluation of welds Verity® is used in conjunction with a master SN curve also developed by the same authors. The present paper proposes a frequency domain variant of the Verity® Method to be used in random vibration fatigue applications along with Dirlik and T&B methods. Frequency domain approaches enjoy the statistical advantage of using probability density functions instead of rainflow cycle counters, which offers computational benefits (in terms of time) in multi-channel long history scenarios. This paper thoroughly describes the proposal and shows an exa ple of its application to a brake chamber support attached to the rear axle of a light-duty truck. Verity is used in the both the time and frequency domains and the fatigue results are compared. a Dassault Systèmes Simulia R&D, Sheffield S1 4LW, UK b Volkswagen C&O, Resende, CEP 27537-803, Brazil a Dassault Systèmes Simulia R&D, Sheffield S1 4LW, UK b Volkswagen C&O, Resende, CEP 27537-803, Brazil

© 2019 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Fatigue Design 2019 Organizers. © 2019 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Fatigue Design 2019 Organizers. © 2019 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Fatigue Design 2019 Organizers. Keywords: Verity®, frequency domain, fatigue, welded joints, structural stress method Keywords: Verity®, frequency domain, fatigue, welded joints, structural stress method

1. Introduction There are a large number of methods available for evaluating fatigue of welds which are basically classified as local or global approaches. The global approaches refer to those assessments based on nominal stresses or on the applied 1. Introduction There are a large number of methods available for evaluating fatigue of welds which are basically classified as local or global approaches. The global approaches refer to those assessments based on nominal stresses or on the applied

2452-3216 © 2019 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Fatigue Design 2019 Organizers. 2452-3216 © 2019 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Fatigue Design 2019 Organizers.

2452-3216 © 2019 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Fatigue Design 2019 Organizers. 10.1016/j.prostr.2019.12.020