My SAE WCX 2022 Top Takeaway

 

SAE WCX | Detroit, Michigan | April 5-7, 2022

There were several papers on fatigue life prediction for elastomers at SAE WCX 2022, but the highlight for us was this one from Automotive OEM Stellantis: “Fatigue Life Prediction and Correlation for Powertrain Torque Strut Mount Elastomeric Bushing Application” by Dr. Touhid Zarrin-Ghalami, Durability Technical Specialist at FCA US LLC Fiat Chrysler Automobiles logowith coauthors C Elango, Sathish Kumar Pandi, and Roshan N. Mahadule from FCA Engineering India Pvt, Ltd.  Check out the abstract or buy the paper here…

The study shows that very accurate fatigue life prediction results are possible for elastomeric components under block cycle loading using Critical Plane Analysis.  A key feature of the analysis is the characterization and modeling of rubber’s hyperelastic properties, fatigue crack growth properties, crack precursor size, and strain crystallization behavior.  Careful measurement of these analysis ingredients led to a nearly perfect correlation of the predicted life (520 blocks) with the tested life (523 blocks, average of 4 replicate tests), and of predicted failure mode with observed failure mode.

Endurica users like Stellantis are developing a solid track record of routine and successful fatigue life prediction.  We soon expect to see the day when CAE fatigue life prediction for rubber components is regarded as obligatory, given the risk and cost avoided with “right the first time” engineering.

Congratulations to the Stellantis team on this impressive success!

 Fatigue Life (block) demonstrating the accuracy of the CAE Virtual Simulation compared to a physical test

Citation: Elango, C., Pandi, S.K., Mahadule, R.N., and Zarrin-Ghalami, T., “Fatigue Life Prediction and Correlation of Engine Mount Elastomeric Bushing using A Crack Growth Approach,” SAE Technical Paper 2022-01-0760, 2022, doi:10.4271/2022-01-0760.

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