The durability evaluation of overhanging components of a vehicle (Ex: horn, radiator) is a challenge to durability engineers as resonance plays an important role in determining their fatigue life. As resonance cannot be avoided always, it is desirable to develop methods to evaluate life of the component in the presence of resonance.
Though the existing vibration test standards suggest test profiles to evaluate resonance failures, there are cases in which, these methods do not yield the proving ground results. This may lead to unnecessary overdesign or unrealistic failures. In such cases it is suggested to generate a sweep endurance test procedure customized to the proving ground or actual roads. This paper studies a methodology for generating a sweep endurance test procedure for evaluation of resonating components.
Responses like stress and accelerations were measured in test components in proving ground. Contribution of each frequency band towards overall damage is determined. An optimized test profile was generated using the proving ground stress data and identified frequency band while retaining the failure modes.
Further, the test profile is simulated using CAE and responses are compared with the responses of rig. Life/Damage in rig and CAE is correlated. This approach can be used to evaluate counter measures in CAE in early stage of development, saving development cost and time.
Same has been explained with case study of canister bracket in this paper.