Methodology for failure simulation Using 4 corner 6 DOF Road load simulator of Overhanging Components: An Experimental Approach
To be published on November 21, 2019 by SAE International in United States
Event: NuGen Summit
Nowadays, Road Load Simulators are used by automobile companies to reproduce the accurate and multi axial stresses in test parts to simulate the real loading conditions. The road conditions are simulated in lab by measuring the customer usage data by sensors like Wheel Force transducers, accelerometers, displacement sensors and strain gauges on the vehicle body and suspension parts. The acquired data is simulated in lab condition by generating ‘drive file’ using the response of the above mentioned sensors. For generation of proper drive file, not only good FRF but ensuring stability of inverse FRF is also essential. Stability of the inverse FRF depends upon the simulation channels used. In this paper, an experimental approach was applied for focused failure simulation of engine mount, one of such low correlation zone, with known history of failure. Methodology was established to simulate proving ground loads on engine mount along with simulation of loads at wheel center using a 4 corner 6 DOF road load simulator. Result was verified by endurance run on test rig and matching the nature of failure of test rig and actual failure history. Repeatability of the failure was also ensured using the same simulation model.