Fatigue life prediction of MIG - Welded Aluminium Structures

1.

Virtual fatigue life prediction in developement of Aluminium Space Frames

Analysis methods and its influence in car frame concept developement
Difficulties in usage of virtual fatigue life prediction methods

2.

Main tasks for fatigue life analysis in the Aluminum Space Frame
Material combinations and joining techniques

3.

One step testing in correlation to FEMFAT WELD analysis

T-joint specimen
H-specimen
Peeling-specimen

4.

FEMFAT WELD damage analysis in correlation to real car frame testing

Longitudinal Side Vertical testing in relation to the Audi A2

5.
31.Mai 2001

Summary
P. Haffner

N/EL-3

Fatigue life prediction of MIG - Welded Aluminium Structures

Virtual fatigue life prediction in developement of Aluminium Space Frames
Analysis methods and its influence in car frame concept developement
Prediction poignancy of FE - Methods is improving steadily
Predictions from crash-, dynamics- and stress analysis have become a major influence on the
construction of modern car frames
The bandwidth between optimised function compliance and structural reserves is getting smaller
Predictions of fatigue life for the complete car frame come mostly from real car testings, like actual
driving tests or testing rigs

Aim: Integration of the virtual fatigue life prediction methods into the early developement process

31.Mai 2001

P. Haffner

N/EL-3

Fatigue life prediction of MIG - Welded Aluminium Structures

Virtual fatigue life prediction in developement of Aluminium Space Frames
Difficulties in usage of virtual fatigue life prediction methods:

Bg effort required to create accurate FE - models and the emulation of joining techniques

Emulation of the boundary conditions

- Definition of the bearing block location in the Space Frame model

- Definition of the load input locations in the Space Frame model
- Modelling of the interface areas to the axis system
- Transmission of the load- time dependencies from wheel to frame

31.Mai 2001

P. Haffner

N/EL-3

Fatigue life prediction of MIG - Welded Aluminium Structures

Main tasks for fatigue life analysis in the Aluminium Space Frame
Material combinations and joining techniques
profile - profile

(MIG)

casting - profile

(MIG, laser)

casting - casting (MIG)

Priority:

Example:

31.Mai 2001

sheet - profile

(riveting, laser, MIG)

sheet - casting

(riveting, laser)

Predicting of MIG und Laserweld behavior in the areas around the

load input locations

Load input through shock absorber and axis frame connections

P. Haffner

N/EL-3

Fatigue life prediction of MIG - Welded Aluminium Structures

Main tasks for fatigue life analysis in the Aluminium Space Frame
Example: Shock absorber connection area, Audi A2 (current state)
Casting parts

MIG welding
Connection to the longitutinal beam

31.Mai 2001

P. Haffner

N/EL-3

Fatigue life prediction of MIG - Welded Aluminium Structures

One step testing in correlation to FEMFAT WELD analysis

T - joint

Fatigue testing on T-joint-specimen

31.Mai 2001

P. Haffner

N/EL-3

Fatigue life prediction of MIG - Welded Aluminium Structures

One step testing in correlation to FEMFAT WELD analysis

T - joint

Profile cross sections used in the testings

31.Mai 2001

P. Haffner

N/EL-3

Fatigue life prediction of MIG - Welded Aluminium Structures

One step testing in correlation to FEMFAT WELD analysis

T - joint

FE - Model and weld definition

Element edge length 5mm
Edge Element thickness increased
for profile P2

a
b

Welding area
a T-joint weld
b butt weld

R = 1 mm

clamped boundarys
31.Mai 2001

P. Haffner

N/EL-3

Fatigue life prediction of MIG - Welded Aluminium Structures

One step testing in correlation to FEMFAT WELD analysis

T - joint

Results of NASTRAN stress analysis

Nodal stresses v. Mises
Bending stress amplitude = 40 MPa

Profilform : P2

40

Von Mises Spannunegen [ MPa ]

35

30

25

P2
P3

20

Profilform : P3

15

10

0
0

10

20

30

40

50

60

70

80

90

100 110 120 130 140 150 160 170

Knotennummern

31.Mai 2001

P. Haffner

N/EL-3

Fatigue life prediction of MIG - Welded Aluminium Structures

One step testing in correlation to FEMFAT WELD analysis
FEMFAT WELD damage plot

T - joint

Crack initiation area in testing

Standard element edge length 5mm

Model : R = 1 mm

Profil P3

Stress ratio = -1
Bending stress amplitude = 40 MPa
Cycles to Failure = 900
Maximum damage = 1.0
31.Mai 2001

P. Haffner

N/EL-3

Fatigue life prediction of MIG - Welded Aluminium Structures

One step testing in correlation to FEMFAT WELD analysis

T - joint

Testing results in correlation to FEMFAT WELD Damage analysis

Aluminium T-Sto Verbindung

Aluminium t-joint specimen

100

bending stress amplitude s[MPa]

Biegenennspannungsamplitude
[MPa]

Versuchsergebnisse
P2, P3P3
testing
results P2,

10

FEMFAT FEMFAT-Ergebnisse
WELD results

P3
P2

1
1,00E+01

1,00E+02

1,00E+03

1,00E+04

1,00E+05

1,00E+06

1,00E+07

Anrischwingspielzahl
cycles to failure Na
31.Mai 2001

P. Haffner

N/EL-3

Fatigue life prediction of MIG - Welded Aluminium Structures

One step testing in correlation to FEMFAT WELD analysis

31.Mai 2001

H - specimen

P. Haffner

N/EL-3

Fatigue life prediction of MIG - Welded Aluminium Structures

One step testing in correlation to FEMFAT WELD analysis

H - specimen

Load application
Overlap weld
MIG 3x50 mm

clamped boundary on bottom side

31.Mai 2001

P. Haffner

N/EL-3

Fatigue life prediction of MIG - Welded Aluminium Structures

One step testing in correlation to FEMFAT WELD analysis

H - specimen

Testing results in correlation to FEMFAT WELD damage analysis

H-Specimen: Overlap MIG Weld 3x50mm
Material: A6009
Comparison of Mean Stress infuence

1,00E+05

r = -1
r = 0.1

Loadamplitude
Amplitude [N]
(N)
load

testing (r = 0.1)

k = 4.06

k = 4.00

k = 4.04
1,00E+04
1,00E+02

1,00E+03

1,00E+04

1,00E+05

1,00E+06

cycles
to failure
Cycles
31.Mai 2001

P. Haffner

N/EL-3

Fatigue life prediction of MIG - Welded Aluminium Structures

One step testing in FEMFAT WELD analysis

Peeling - specimen

Load application

Overlap weld

clamped boundary

31.Mai 2001

P. Haffner

N/EL-3

Fatigue life prediction of MIG - Welded Aluminium Structures

One step testing in FEMFAT WELD analysis

Peeling - specimen

Results from FEMFAT WELD damage analysis

Peeling specimen: Overlap MIG Weld
Material: AlMgSiMn
Comparison of Mean Stress influence
1,00E+04
r = -1
r = 0.1

Loadamplitude
Amplitude (N)
load
[N]

k = 4.45

k = 4.62
1,00E+03

1,00E+02
1,00E+02

1,00E+03

1,00E+04

1,00E+05

1,00E+06

cycles
to failure
Cycles
31.Mai 2001

P. Haffner

N/EL-3

Fatigue life prediction of MIG - Welded Aluminium Structures

Car frame testing
Testing rig configuration
Longitudinal Side Vertical testing (LSV)
Driving measurement
Forces, Moments on the wheel

Fk(t), M k (t), k=x,y,z

Testing VA, HA
6 Hydrolic cylinders
Car frame clamped
Springs/damper as
rigid beams
31.Mai 2001

P. Haffner

N/EL-3

Fatigue life prediction of MIG - Welded Aluminium Structures

FEMFAT WELD damage analysis in correlation to real car frame testing

Audi A2
(early state of
developement)

FZ, MZ
FX, MX

Overlap weld

Load- time
dependencies
in wheel mid-point

FY, MY

T-joint weld
Car frame interface
areas

31.Mai 2001

P. Haffner

N/EL-3

Fatigue life prediction of MIG - Welded Aluminium Structures

FEMFAT WELD damage analysis in correlation to real car frame testing

Audi A2
(early state of
developement)

FZ, MZ
FX, MX

Crack prediction from

FEMFAT WELD
Overlap weld

Load- time
dependencies
in wheel mid-point

FY, MY

T-joint weld
Car frame interface
areas

31.Mai 2001

P. Haffner

N/EL-3

Fatigue life prediction of MIG - Welded Aluminium Structures

FEMFAT WELD damage analysis in correlation to real car frame testing
FEMFAT WELD damage analysis in correlation to testing reults

FEMFAT WELD damage Plot

Crack predicton from FEMFAT WELD

Audi A2
(early state of
developement)

Testing results

cracks on MIG- welds

Fatigue life prediction < 200 km EVP

Fatigue life ca. 8000 km EVP

ca. 4000 km normal driving

ca. 160000 km normal driving

31.Mai 2001

P. Haffner

N/EL-3

Fatigue life prediction of MIG - Welded Aluminium Structures

Shock absorber connection area optimised for fatigue

Audi A2
(current state)

The FEMFAT WELD prediction poingnancy was comparable to a vertical load stress
analysis at the shock absorber connection
The optimisation in the welding areas is done by the classic stress analysis
Real testings were nessecary for cross validation
31.Mai 2001

P. Haffner

N/EL-3

Fatigue life prediction of MIG - Welded Aluminium Structures

Summary
One step testing
Damage locations are correctly identified
Fatigue life prediction until crack initiation is on the conservative side
Predictions with mean stress influence lead, in some cases, to disproportional results
This effect is more noticable under peeling conditions than under shear tension
Car frame testing
The location of first crack initiation can be identified with relatively high confidence
Other real crack locations are also able to be predicted using FEMFAT WELD
However, not all cracks can be identified
There are also cracks identified with FEMFAT WELD, that are not problematic in real testings
Absolute fatigue life predictions with FEMFAT WELD for particular weldings are extremly conservative

31.Mai 2001

P. Haffner

N/EL-3

Fatigue life prediction of MIG - Welded Aluminium Structures

For the FEMFAT WELD tool to be as powerful as crash simulation

in the Space frame concept developement, it is required to get the
prediction much closer to the real fatigue life time

31.Mai 2001

P. Haffner

N/EL-3