۱٫ Introduction

۲٫ Trailer FEA model

۳٫ Fatigue enhanced structural stress analysis

۴٫ Vehicles inspection and comparison

۵٫ Conclusion

Acknowledgements

References

A FE seam weld model has been built for advanced fatigue structural stress analysis. The shell element model allows both weld toe and weld root fatigue assessment. In order to validate the model, this project deals with the complete analysis of a last decade manufactured vehicle for which experience feedback is possible. The vehicle structure is mainly built with steel sheets and the assembly is performed by seam welding. Shell element model is appropriate for FEA. The entire FEM preparation is presented hereafter and each step is detailed: 3D CAD weld building, mid-surface idealization, weld leg imprint creation, weld mesh connection and load application. Fatigue analysis is performed based on a fatigue limit approach and IIW FAT data. For every structure location a Haigh diagram is built. Different diagrams are presented for plain metal, cut edge, weld toe and weld root. The FEA results are post processed and each appropriate tensor component is taken into account. For plain metal, stress variation along the worst principal stress orientation is calculated. In welds, for both toe and root locations, the structural stress computation based on grid point forces extraction is described. Longitudinal shear stress in weld and at weld toe as well as weld longitudinal normal stress calculations are detailed. Fatigue results are displayed for each location over the whole chassis model. Finally, vehicles built during the last decade are inspected back from the customers experience field. Observed crack types and locations are compared to fatigue analysis predictions.

Introduction

LOHR Industrie products car carrier vehicles, railway semi-trailer transport systems and urban electric people transportation solutions. All products are steel made and assembled by welding. For vehicle structure analysis, LOHR Industrie has developed FEA models for assemblies relative to seam weld and bolt [1]. Seam weld fatigue assessment model has been described in numerous publications [2, 3, 4] and validation based on simple assembly specimens has been detailed. A project has been launched in order to verify the proposed FEA model and the associated fatigue behaviour prediction by comparison with long mileage vehicle structure inspections. An old generation car carrier trailer model is built. The fatigue analysis based on advanced structural stress approach is performed.