PSI - Issue 57

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ScienceDirect

Procedia Structural Integrity 57 (2024) 731–742 Structural Integrity Procedia 00 (2023) 000±000 Structural Integrity Procedia 00 (2023) 000±000

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Fatigue Design 2023 (FatDes 2023) Fatigue Design 2023 (FatDes 2023)

© 2024 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0 ) Peer-review under responsibility of the scientific committee of the Fatigue Design 2023 organizers © 2023 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http: // creativecommons.org / licenses / by-nc-nd / 4.0 / ) Peer-review under responsibility of the scientific committee of the Fatigue Design 2023 organizers. Modern vehicles contain numerous subsystems for comfort, safety, electrification and autonomous driving functions that are mounted to the body-in-white structure. These subsystems are submitted to stochastic vibrational loads induced mainly by the road unevenness. The vibration fatigue behaviour of the subsystems and their connection to the body-in-white structure depend on a great number of influence parameters and associated uncertain scatter bands that are usually unknown and di ffi cult to consider in the design process. This study investigates the oscillation behaviour and fatigue life of a current car component excited by vi brational loads focusing on scatter of relevant influence parameters (mass, sti ff ness) on a pronounced statistical sample basis. An experimental modal analysis is used to determine eigenmodes and damping characteristics for the three variants: nominal value, increased mass and reduced sti ff ness. As a further experimental investigation vibration fatigue tests are performed. A probabilistic approach using a simulation tool chain with the aid of commercial computer aided engineering (CAE) programs is proposed to consider scatter e ff ects on the fatigue life of the component submitted to vibration loads and its connection to the body-in-white structure. The simulation fidelity when using uncertain broader scatter bounds is compared to simulation fidelity using both mea sured data and modal analysis output. Furthermore, correlations between the vibration behaviour and the fatigue of the component are derived. Finally, the hardware fatigue tests results are compared to the simulation results. A very good agreement for eigen modes, frequency response functions and fatigue lifetime was observed between simulation model and experimental findings. A significant accuracy improvement of the fatigue life simulation using the introduced probabilistic simulation method considering measured scatter bounds for uncertain input parameters is presented. © 2023 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http: // creativecommons.org / licenses / by-nc-nd / 4.0 / ) Peer-review under responsibility of the scientific committee of the Fatigue Design 2023 organizers. Modern vehicles contain numerous subsystems for comfort, safety, electrification and autonomous driving functions that are mounted to the body-in-white structure. These subsystems are submitted to stochastic vibrational loads induced mainly by the road unevenness. The vibration fatigue behaviour of the subsystems and their connection to the body-in-white structure depend on a great number of influence parameters and associated uncertain scatter bands that are usually unknown and di ffi cult to consider in the design process. This study investigates the oscillation behaviour and fatigue life of a current car component excited by vi brational loads focusing on scatter of relevant influence parameters (mass, sti ff ness) on a pronounced statistical sample basis. An experimental modal analysis is used to determine eigenmodes and damping characteristics for the three variants: nominal value, increased mass and reduced sti ff ness. As a further experimental investigation vibration fatigue tests are performed. A probabilistic approach using a simulation tool chain with the aid of commercial computer aided engineering (CAE) programs is proposed to consider scatter e ff ects on the fatigue life of the component submitted to vibration loads and its connection to the body-in-white structure. The simulation fidelity when using uncertain broader scatter bounds is compared to simulation fidelity using both mea sured data and modal analysis output. Furthermore, correlations between the vibration behaviour and the fatigue of the component are derived. Finally, the hardware fatigue tests results are compared to the simulation results. A very good agreement for eigen modes, frequency response functions and fatigue lifetime was observed between simulation model and experimental findings. A significant accuracy improvement of the fatigue life simulation using the introduced probabilistic simulation method considering measured scatter bounds for uncertain input parameters is presented. Keywords: Vibration fatigue; modal analysis; uncertainty; stochastic; Monte-Carlo-Simulation; mass force excited component; automotive Keywords: Vibration fatigue; modal analysis; uncertainty; stochastic; Monte-Carlo-Simulation; mass force excited component; automotive Investigation of an automotive subsystem submitted to vibration loads considering scatter of influence parameters SvenMaier a,b, ∗ , Florian Bachmann a , Marc Wallmichrath c a BMW AG, Knorrstr. 147, 80788 Munich, Germany b Technical University of Darmstadt, Karolinenplatz 5, 64289 Darmstadt, Germany c Fraunhofer Institute for Structural Durability and System Reliability LBF, Bartningstr. 47, 64289 Darmstadt, Germany Investigation of an automotive subsystem submitted to vibration loads considering scatter of influence parameters SvenMaier a,b, ∗ , Florian Bachmann a , Marc Wallmichrath c a BMW AG, Knorrstr. 147, 80788 Munich, Germany b Technical University of Darmstadt, Karolinenplatz 5, 64289 Darmstadt, Germany c Fraunhofer Institute for Structural Durability and System Reliability LBF, Bartningstr. 47, 64289 Darmstadt, Germany Abstract Abstract

∗ Corresponding author. Tel.: + 49-89-382-14325 E-mail address: sven.ms.maier@bmw.de ∗ Corresponding author. Tel.: + 49-89-382-14325 E-mail address: sven.ms.maier@bmw.de

2452-3216 © 2024 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of the scientific committee of the Fatigue Design 2023 organizers 10.1016/j.prostr.2024.03.079 2210-7843 © 2023 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http: // creativecommons.org / licenses / by-nc-nd / 4.0 / ) Peer-review under responsibility of the scientific committee of the Fatigue Design 2023 organizers. 2210-7843 2023 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http: // creativecommons.org / licenses / by-nc-nd / 4.0 / ) Peer-review under responsibility of the scientific committee of the Fatigue Design 2023 organizers.