Thermo Mechnical Fatigue Simulations for Turbo Charger Casings in 3DEXPERIENCE

Accelleron (formerly ABB Turbo Systems AG) develops and produces turbochargers for gas and diesel engines with engine outputs of more than 500 kW per turbocharger. The components are exposed to strong thermal and mechanical loads with very long service lives at the same time. In order to meet the high requirements, the components must pass various quality tests. These tests consist of experimental tests and simulations. Accelleron has been working with Catia V5 and AFC to simulate static components since 2005. In recent years, Accelleron has decided to replace the previous PDM system and convert the entire CAD environment, including the simulation for static parts, to 3DExperience. Since 2023, the entire structural mechanics team at Accelleron is working with 3DExperience. For the introduction of 3DExperience in the simulation area, tests of the software have been taking place since 2021. The lecture shows the structure of models for calculating the thermo-mechanical fatigue of turbocharger components. In addition, certain insights into sub-processes such as the application of thermal loads or the use of different screw variants are shown.

Presenter: Matthias RICHNER, Accelleron Turbo Systems Switzerland Ltd.

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Virtual Qualification of the Durability Performance of an Elastomeric Mount with Endurica

An elastomeric mount sees complex loads in service, and engineers must show that the mount can endure those loads. This presentation shows how the entire qualification procedure used by Ford for an elastomeric motor mount can be simulated in Abaqus and post-processed with Endurica. The loading

schedule is composed of 144 different events recorded at the test track, each having as many as 6 input channels (3 forces and 3 moments). The analysis begins by computing a nonlinear map of finite element model stress-strain fields to a series of sampling points in the global load input space. This map is then used in Endurica EIE to rapidly generate full transient stress-strain history (15.6 million time steps!) for each finite element. This process produces 3.2 TB of stress-strain history, which is then passed to Endurica CL to solve for fatigue life. The analysis takes into account the elastomer’s nonlinear material properties, and correctly predicts failure location and fatigue life. The entire process was executed in 90 hours of compute time.

Presenter: Thomas G. EBBOTT, Endurica LLC

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Variability Of Fatigue Simulation Predictions For Automotive Components

Nowadays, product validation focuses on fatigue-designed components for reliability of downsized and cost-effective parts. Finite Element Analysis (FEA) replaces costly and time-consuming laboratory tests and has a positive environmental impact by reducing the carbon footprint and scrap. Particularly for vibration, the validation of complex systems in the high cyclic fatigue domain involves expensive and time-consuming rig tests with potentially variable results. For this reason, within Valeo THS, we have developed methods & tools for a more tailored approach, where the design is validated by FEA simulations based on vibration fatigue criteria. In this framework, the risk related to the variability of the fatigue life is evaluated, so that it is possible to quantify the uncertainty of the estimated reliability. DOE method was proposed with applied superelement. The goal is to set the “damage life margins” resulting from boundary limits of those parameters. We present a real case study of an engine cooling system subjected to random vibration loadings, and we examine the effect of the simulation parameters on engine cooling module components' fatigue life predictions.

Presenter: Ewelina CZERLUNCZAKIEWICZ & Maciej MAJERCZAK, Valeo THS

Automated standard-compliant and verifiable weld seam assessment in Abaqus

Welds under cyclic loads are, in the vast majority of cases, the weak points of a structure that fail first. The verification is carried out according to rules, such as the international standards: IIW Recommendations [2], European rules: Eurocode 3 and 9 [3] and national regulations: FKM Guideline [1]. With the spread of computer-aided virtual product simulation, methods based on structural stresses or notch stresses have become state of the art. With these methods, the stresses at the weld toe or in the weld root can be directly determined and verified for almost any weld seam. In the structural stress concept, the stress is extrapolated according to IIW guideline on the sheet surface at defined distances towards the weld toe. (Fig. 1) In the notch stress method, a fictitious notch radius at the weld toe and in the weld root is introduced into the simulation model. This method currently represents the state of the art for the weld root. (Fig. 1) The determination of the local stresses at the weld seams and their evaluation is not economically possible for many seams without special software. In this presentation, a software is presented that makes it possible to carry out both the structural stress and the notch stress assessment along the seam in Abaqus automatically. It is thus possible to examine a large number of seams in a short time in a standard-compliant and verifiable manner (Fig. 2). The use of the software within Abaqus is demonstrated with examples. Results on different welded joints with the different verification methods are presented and compared with each other.

Presenter: Tim KIRCHHOFF, ihf Ingenieurgesellschaft mbH

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