New Method for Evaluation of Adhesive Joint Failure Under Cyclic Loads

Innovative lightweight design is the key to reducing consumption and pollutant emissions. Especially the paradigm shift currently underway towards more electrification demands new possibilities for saving weight to be explored. Thus the aim of this webinar is to show how a fatigue life analysis can be carried out for a modern electric drive system. Since vibration phenomena play an essential role here, a modal fatigue analysis is carried out. We present all the necessary steps to set up the modal fatigue analysis in FEMFAT channelmax and the fatigue results. The e-drive system will be subjected to an engine run-up simulation. The add-on tool HARMONIC is used for the data preparation.

The crankshaft of an engine is a highly dynamically loaded component that is continuously optimized and optimized in terms of design and production technology. In order to be able to reproduce this in the simulation, the essential influences must be considered. This includes the dynamically behaviour in combination with the engine, the material properties and the application of the loads and their transfer to other parts (bearings). The modal approach has established itself as a proven method here, whereby a modal basis is determined in the FEM so that the crankshaft is integrated as a flexible body in the MKS model of the engine, and so that an entire engine run-up can be simulated. The modal participation factors are obtained from the MBS simulation, which are used together with the modal stresses for the safety factor calculation. This workflow requires the combination of different simulation tools. The challenge is to organize the data transfer between the tools efficient and correct. In this example, the workflow is realized using OptiStruct from Altair for FEM calculation, EXCITE from AVL as MKS tool and FEMFAT from Magna Powertrain ECS as Fatigue solver. This makes it possible to simulate a complex engine run-up with consideration of the ignition bearing forces and to calculate the fatigue life of the crankshaft in FEMFAT. This webinar, details of the simulation workflow of the 4-cylinder crankshaft will be presented and the effects of several influencing variables on the fatigue life will be studied.

Typically, in the automotive industry, the numerical fatigue life analysis of seam welds is based on shell models. Determining the local stiffness and the fatigue life of weld details with those models is a challenging task; especially for closely spaced welds as well as for the connection of metal sheets to thick walled or solid components...

FEMFAT headquarters in Austria holds an International user meeting every 2-years, and in spring and autumn, five distributors organize in Shanghai, Tokyo, Michigan, Seoul and Pune regional user meetings with presentations according to the fatigue analysis of their customers. The webinar will show a short summary of four of the presentations which have aroused the interest of the audience. Some have made the “best lecture award.”

Learn about the frequency response capabilities available in FEMFAT's Spectral Module.

Basic introductory slides to durability and fatigue software, FEMFAT.