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Accelerated Durability Bench Test and Risk Assessment: A Case Study
ISSN: 0148-7191, e-ISSN: 2688-3627
Published March 26, 2021 by SAE International in United States
This content contains downloadable datasetsAnnotation ability available
The main goal of this study is to reduce the gearboxes testing time for increasing the availability of dynamometer test benches – and gaining competitive advantage through the fast launch of new products, without jeopardizing the reliability targets. This study is proposed with the modeling, test acceleration, and analysis of its results, based on the theory of materials performance predicted by the Wöhler diagram (B10 life).
The general study approach was to increase the rotational speed of testing machines for decreasing the necessary time with same final number of cycles and damage. Among the risks of this process, there is the probability of introducing failure modes with nonlinear effects, or even that are not representative of the field application. Moreover, the test bench machine might be damaged when the normal setup configurations are exceeded, raising the downtime and causing the opposite effect of the desired.
The investigation starts with the definition of test conditions. From the transmission modelling and simulations based on test configuration, the gearbox is then tested on a machine with similar setup. Parameters as torque, rotational speed, vibration, and oil temperature are monitored during the test to ensure acceptable levels and to examine their influence in the results. During the validation, aspects as joint clearance, maximum water flow for cooling, and dynamic torque effect due to higher rotational speed were tracked. The strategic gear speed choice was based on the test time and usage importance. The test bench has already reported plausible results and a strong potential of test acceleration was identified.
In future, the research will be extended to all gears and dynamometer test benches to elucidate the particularities and restrictions of each option.
CitationTunes, G., Leão, A., Piva, J., Silva, P. et al., "Accelerated Durability Bench Test and Risk Assessment: A Case Study," SAE Technical Paper 2020-36-0156, 2021, https://doi.org/10.4271/2020-36-0156.
Data Sets - Support Documents
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- González Rey Gonzalo Estimating gear fatigue life Gear Solutions 7 82 88 2006
- Naunheimer H. , Bertsche B. , Ryborz J. , Novak W. Automotive transmissions: Fundamentals, selection, design and application 10.1007/978-3-642-16214-5 2011
- Piva J.I. , Pavan J. V. Proposal for a new approach to transmission bearing approval SAE Brasil Congress and Exhibit 2007
- Killedar J. S. Dynamometer: “Theory and Application to Engine Testing USA Xlibris 2012