Durability Evaluation of Tipper Cabin through Virtual Multi-Axis Cab Shake Test

Durability Evaluation of Tipper Cabin through Virtual Multi-Axis Cab Shake Test

Srinivas Kurna

Ashutosh Dubey

Durability Evaluation of Tipper Cabin through Virtual Multi-Axis Cab Shake Test

Objective

Life Evaluation and Underbody Design finalization of Truck Cabin for Tipper
applications

Based on Fatigue Correlation between Virtual Transient Simulation and 5-Axis Rig
Test.

To validate Life of Cab BIW & Suspensions, reducing physical endurance testing
to minimum.

Durability Evaluation of Tipper Cabin through Virtual Multi-Axis Cab Shake Test

Challenges:

Test Rig setup has been simulated along with Cabin and Truncated portion of
Chassis for calculating the Life Using FEMFAT.

Multiple design iterations life calculations using FEMFAT to reduce the cost for
several physical validations.

Durability Evaluation of Tipper Cabin through Virtual Multi-Axis Cab Shake Test

Methodology:

Life
Evaluation

Rig Test

CAE

FEMFAT

Fatigue Life

Fatigue Life

Life Correlation

Correlated FE Model

Design Iterations
Pass

Optimized Design

Durability Evaluation of Tipper Cabin through Virtual Multi-Axis Cab Shake Test

Methodology:

Duty Cycles generated from Tipper SLDA is used for 5-Axis Cab shake rig and Virtual Simulation
have been applied in CAE model, similar to test rig setup.

Four vertical excitations have been applied on chassis through 4 posters of test rig. One
longitudinal excitation is also applied to simulate longitudinal loads.

Test rig setup has been simulated and correlated in CAE model

Design Iterations are done Virtually and Life Target achieved through FEMFAT evaluation

Design Finalized virtually is validated by Rig Test & Vehicle Endurance No Failures observed

Durability Evaluation of Tipper Cabin through Virtual Multi-Axis Cab Shake Test

Fatigue Life Calculations Using FEMFAT:

Trans Max Vs Channel Max
FEMFAT

Channel
Max

Trans Max

Transient
Stresses

Fatigue Life

Modal
Stresses

Participation
Factors

Fatigue Life

Durability Evaluation of Tipper Cabin through Virtual Multi-Axis Cab Shake Test

Trans Max Vs Channel Max

Durability Evaluation of Tipper Cabin through Virtual Multi-Axis Cab Shake Test

Rig Test vs. Virtual Test - Animation:

Durability Evaluation of Tipper Cabin through Virtual Multi-Axis Cab Shake Test

Correlation: CAE to Rig

Very good correlations have been achieved between the Test Rig vs. Virtual
simulation results in Displacement/Strain time domain.

Durability Evaluation of Tipper Cabin through Virtual Multi-Axis Cab Shake Test
Measured Strain Damage vs. CAE Damage Values Graph over all Strain Gages
CAE Relative Damage
5

Relative damage

4
3
2
1
0
0

10

11

12

13

14

15

16

Strain Gauge No.

It can be observed from the above relative damage graph that damages in the CAE
results are similar to those in rig. However, they are on slightly higher side.
Therefore, CAE will have conservative results for the cabin life calculation.

Durability Evaluation of Tipper Cabin through Virtual Multi-Axis Cab Shake Test

Conclusions:

Fatigue life analysis results through FEMFAT correlates well with rig testing
results. This has improved confidence on virtual analysis, thereby helped in
reducing rig testing and vehicle endurance testing.

Virtual analysis helped in avoiding rig testing for intermediate iterations

resulting in saving of appx.17.5MINR.

This methodology has become standard practice in VECV. We are now using
same methodology for new vehicle chassis validation also.

Since Fatigue life correlation is very good, we have significantly reduced the
number of physical rig tests as well as vehicle endurance test.