Accelerating Edition Strategy of Load Spectrum for Durability Analysis of Automotive Chassis

doi:10.3901/JME.2020.20.164

Abstract

Abstract: The editing method of load spectrum and the ratio of damage retention affect the quality of load editing together. Based on the steering knuckle's strain data measured in test site, the accelerated spectrum of wheel center six-component force signal with different damage retention proportion is obtained by using damage retention editing method and wavelet transform editing method. The effect of editing methods and editing parameters on quality of accelerated spectrum is analyzed from the aspects of compression efficiency, power spectral density, level-crossing counting, rain flow counting and statistical parameters. The influence of different edition scheme on the accuracy and efficiency of fatigue analysis is compared by fatigue simulation. The results show that the setting of damage retention ratio is not less than 90%, which is the premise of ensuring the editing quality of load spectrum. The fatigue analysis accuracy of damage retention editing method and wavelet transform editing method is close, but the accelerated effect of damage retention editing method is better. Using the damage retention editing method to retain 95% is the best editing scheme, the time compression ratio of the accelerated spectrum is nearly 50%, the simulation error of fatigue life is controlled within 5% and the simulation efficiency is improved by 215%, which provides a reference for improving the editing quality of durability load.

Key words: load spectrum editing, damage retention editing method, wavelet transform editing method, damage retention proportion, fatigue durability simulation

CLC Number:

U467

DONG Guojiang, HAN Jie, YAN Feng, ZHANG Meng. Accelerating Edition Strategy of Load Spectrum for Durability Analysis of Automotive Chassis[J]. Journal of Mechanical Engineering, 2020, 56(20): 164-173.

References

[1] CIANETTI F,ALVINO A,BOLOGNINI A,et al. The design of durability tests by fatigue damage spectrum approach[J]. Fatigue& Fracture of Engineering Materials& Structures,2018,41(4):787-796.
[2] 郑松林,王烁,冯金芝,等.多轴载荷作用下减振器耐久性试验载荷谱编制[J].中国机械工程,2017,28(21):2547-2552. ZHENG Songlin,WANG Shuo,FENG Jinzhi,et al. Load spectrum compilation of damper durability tests based on multi-axial loads[J]. Journal of China Mecha-nical Engineering,2017,28(21):2547-2552.
[3] 钟响亮.多轴随机振动加速疲劳载荷谱编制方法研究[D].成都:西南交通大学,2017. ZHONG Xiangliang. Research on accelerated fatigue spectrum editing methods of multi-axial random vibra-tion[D]. Chengdu:Southwest Jiaotong University,2017.
[4] 花菲菲,郑松林,冯金芝,等.基于时域损伤编辑法的整车道路模拟试验谱编制[J].机械强度,2015,37(5):964-971. HUA Feifei,ZHENG Songlin,FENG Jinzhi,et al. Spectrum compilation for vehicle road simulation test based on time correlated fatigue analysis with damage editing method[J]. Journal of Mechanical Strength,2015,37(5):964-971.
[5] 于佳伟,郑松林,冯金芝,等.某轿车前副车架服役载荷模拟试验加速方法研究[J].机械工程学报,2016,52(22):112-120. YU Jiawei,ZHENG Songlin,FENG Jinzhi,et al. Research on accelerated testing method for the service-simulation fatigue test of automotive front sub-frame[J]. Journal of Mechanical Engineering,2016,52(22):112-120.
[6] 郑松林,周亚捷,冯金芝,等.一种新的考虑伪损伤保留的道路载荷模拟试验加速方法[J].机械强度,2017,39(2):410-416. ZHENG Songlin,ZHOU Yajie,FENG Jinzhi,et al. A new spectrum development methodology based on pseudo damage reserving for road load simulation test[J]. Journal of Mechanical Strength,2017,39(2):410-416.
[7] 郑国峰,上官文斌,韩鹏飞,等.基于小波变换的汽车零部件加速耐久性载荷谱编辑方法研究[J].机械工程学报,2017,53(8):124-131. ZHENG Guofeng,SHANGGUAN Wenbin,HAN Pengfei,et al. Study of load spectrum edition method based on the wavelet transform to the accelerated durability test of the vehicle component[J]. Journal of Mechanical Engineering,2017,53(8):124-131.
[8] 郑国峰.典型汽车部件载荷谱及加速耐久性编辑与实验方法研究[D].广州:华南理工大学,2017. ZHENG Guofeng. Studies on load spectrum and acceler-ated durability test methods to typical automotive parts[D]. Guangzhou:South China University of Technology,2017.
[9] 郑国峰,上官文斌,韩鹏飞,等.基于小波变换的汽车零部件加速耐久性多轴载荷谱编辑方法研究[J].机械工程学报,2018,54(10):156-166. ZHENG Guofeng,SHANGGUAN Wenbin,HAN Pengfei,et al. Study of multi-axis load spectrum edition method based on the wavelet transform to the accelerated durability test of the vehicle components[J]. Journal of Mechanical Engineering,2018,54(10):156-166.
[10] 朱茂桃,吴新佳,郑国峰,等.基于短时傅里叶变换的汽车零部件耐久性载荷信号编辑方法[J].机械工程学报,2019,55(4):126-134. ZHU Maotao,WU Xinjia,ZHENG Guofeng,et al. Load signal edition method based on the short-time Fourier transform to durability test of vehicle component[J]. Journal of Mechanical Engineering,2019,55(4):126-134.
[11] PUTRA T E,ABDULLAH S,SCHRAMM D,et al. The need to generate realistic strain signals at an automotive coil spring for durability simulation leading to fatigue life assessment[J]. Mechanical Systems and Signal Processing,2017,94:432-447.
[12] PUTRA T E,ABDULLAH S,SCHRAMM D,et al. FCM-based optimisation to enhance the morlet wavelet ability for compressing suspension strain data[J]. Procedia Materials Science,2014,3:288-294.
[13] PRATUMNOPHARAT P,LEUNG P S,COURT R S. Wavelet transform-based stress-time history editing of horizontal axis wind turbine blades[J]. Renewable Energy,2014,63(1):558-575.
[14] 钱立军,吴道俊,杨年炯,等.基于室内道路模拟技术的整车加速耐久性试验的研究[J].汽车工程,2011,33(2):91-96. QIAN Lijun,WU Daojun,YANG Nianjiong,et al. A research on vehicle accelerated durability test based on indoor road simulation technology[J]. Automotive Eng-ineering,2011,33(2):91-96.
[15] 邹喜红,杨真亮,袁冬梅,等. DCT关键零部件道路模拟加速可靠性试验方法的研究[J].汽车工程,2016,38(6):783-790. ZOU Xihong,YANG Zhenliang,YUAN Dongmei,et al. A study on the method of road simulation accelerated reliability test for DCT key components[J]. Automotive Engineering,2016,38(6):783-790.
[16] TAY D,ORTEGA A. Bipartite graph filter banks:polyphase analysis and generalization[J]. IEEE Transac-tions on Signal Processing,2017:1-1.
[17] SAPIETA M,SAPIETOVA A,GAJDOS L. Determine the fatigue life of flange of bearings test station[J]. Procedia Engineering,2017,177(Complete):548-553.
[18] 吴道俊.客车道路载荷谱分析与疲劳编辑研究[J].农业装备与车辆工程,2016,54(3):49-54. WU Daojun. Research on analysis and fatigue editing of bus road load spectrum[J]. Agricultural Equipment& Vehicle Engineering,2016,54(3):49-54.
[19] ABRY J,MITTELHAEUSER C,WOLF S,et al. Enhanced fatigue structural stress analysis of a heavy vehicle seam welded steel chassis frame:FEA model preparation,weld model description,fatigue stress calculation and correlation with 10 year operating experience[J]. Procedia Engineering,2018,213:539-548.
[20] PUTRA T E,ABDULLAH S,SCHRAMM D,et al. Reducing cyclic testing time for components of autom-otive suspension system utilising the wavelet transform and the Fuzzy C-Means[J]. Mechanical Systems& Signal Processing,2017,90:1-14.
[21] 翟新婷,张晓晨,江柱锦,等.基于混合分布的轮式装载机半轴载荷谱编制[J].农业工程学报,2018,34(8):78-84. ZHAI Xinting,ZHANG Xiaochen,JIANG Zhujin,et al. Load spectrum compiling for wheel loader semi-axle based on mixed distribution[J]. Transactions of the Chinese Society of Agricultural Engineering,2018,34(8):78-84.
[22] 曾文豪.汽车铝合金转向节结构拓扑优化与有限元分析[D].广州:华南理工大学,2018. ZENG Wenhao. Structural topology optimization and finite element analysis of vehicle aluminum alloy steering knuckle[D]. Guangzhou:South China University of Technology,2018.
[23] RANI S,AGRAWAL A K,RASTOGI V. Vibration analysis for detecting failure mode and crack location in first stage gas turbine blade[J]. Journal of Mechanical Science and Technology,2019,33(1):1-10.
[24] 曹斌.基于刚柔耦合客车车身结构疲劳寿命分析[D].长春:吉林大学,2018. CAO Bin. Fatigue life analysis of bus body frame based on rigid-flexible coupling method[D]. Changchun:Jilin University,2018.