A Verified and Efficient Approach Towards Fatigue Validation of Safety Parts*

Stefan Weihe; Nicolas Weigel; Klaus Dreßler; Michael Speckert; Sascha Feth

doi:10.3139/120.110249

Article

A Verified and Efficient Approach Towards Fatigue Validation of Safety Parts*

Stefan Weihe , Nicolas Weigel , Klaus Dreßler , Michael Speckert and Sascha Feth

Published/Copyright: May 28, 2013

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From the journal Materials Testing Volume 53 Issue 7-8

Abstract

In the automotive industry, safety parts must be designed according to the state of the art of science and technology such that they do not fail as long as the vehicle is used according to its purpose and misuse of the vehicle does not exceed a reasonably expectable degree. Due to scatter in customer loads and component properties, fatigue validation needs to be based on statistical methods. Mathematically sound methods are devised in order to make the validation process as efficient as possible. They allow considering all test results, including censored test data (e.g. tests suspended due to premature failure of components which are not under consideration). Furthermore, these methods permit adapting the success run criterion successively to the testing process.

Kurzfassung

Abgesicherter und effizienter Nachweis sicherheitsrelevanter Bauteile. Sicherheitsrelevante Bauteile sind in der Automobilindustrie so auszulegen, dass sie im Rahmen von bestimmungsgemäßer Verwendung oder vorhersehbarer Fehlanwendung Sicherheit und Gesundheit nicht gefährden. Aufgrund der Streuungen in Beanspruchung und Beanspruchbarkeit ist dieser Nachweis mit statistischen Methoden zu führen. Um diesen Nachweis möglichst effizient zu erbringen, wurden mathematisch fundierte Auswertemethoden entwickelt, die auch Durchläufer, Ausfälle vor Erreichen der Solllaufzeit und Versuchsabbrüche verwerten können. Weiterhin ist damit eine dynamische Anpassung des Versuchsplans an diese Ereignisse möglich.

This contribution has already been published in the DVM-Report 137

Dr. Stefan Weihe, born 1963, achieved his doctoral degree at the Institute for Statics and Dynamics at the University of Stuttgart after studying Aerospace Engineering (University of Stuttgart) and Civil Engineering (University of Colorado, Boulder). After working as technical referee at the Audi AG he was heading the Department Strength at the Daimler AG since 2002, being responsible for load measurement, load assumptions and durability tests for approval of fatigue strength. In 2007, he became head of the competence center for car bodies and strength in the Van section of the Daimler AG.

Dr. Nicolas Weigel, born 1970, studied Aerospace Engineering at the University of Stuttgart and the Rensselaer Polytechnic Institute and achieved in 2000 his doctoral degree at the Institute for Statics and Dynamics at the University of Stuttgart. After working as a calculation engineer at the EADS Space Transportation, he is working in the department for car bodies and strength in the van section of the Daimler AG since 2005, with focussed tasks on testing, simulation, and statistical assurance of chassis and safety relevant components.

Dr. Klaus Dreßler, born 1961, studied Mathematics and Physics at the University of Kaiserslautern and at the Duke University, N.C. (USA). In 1988 he achieved his doctoral degree in Applied Mathematics. From 1990 until 2003 he first built up the fatigue section at the TECMATH GmbH (since 1997: LMS International) and then was heading the sections MKS and fatigue. Since 2003, he is head of the Department Mathematical Methods in Dynamics and Strength at the Fraunhofer ITWM in Kaiserslautern.

Dr. Michael Speckert, born 1958, achieved his doctoral degree in 1990 after finishing his studies of Mathematics and Physics at the TU Kaiserslautern. Form 1991until 1997 he was working at the TECMATH GmbH in Kaiserlautern and from 1997until 2004 he was working at the LMS Germany. Main topics of his work during this time covered mathematical procedures and software development in the load data analysis and life time calculation. Since April 2004, he is working at the Fraunhofer ITWM in Kaiserslautern in the Department Mathematical Methods in Dynamics and Strength. His work here covers load data analysis and statistical methods for derivation and load assamption as well as modelling and simulation of mechanical systems with methods of the MKS and FEA.

Dr. Sascha Feth, born 1982, studied Mathematics at the University of Kaiserslautern and achieved his doctoral degree in Statistics in 2010. Since 2009, he is working at the Fraunhofer ITWM in Kaiserslautern. In the Department Mathematical Methods in Dynamics and Strength he is especially responsible for the development of the statistics-software Jurojin.

Literature

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Online erschienen: 2013-05-28

Erschienen im Druck: 2011-07-01

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https://doi.org/10.3139/120.110249