Test Correlation of an Exhaust System Durability Failure Using Enhanced CAE Approach 2019-26-0293
Durability of an exhaust system of an automobile is vital to
it's overall performance as well as customer satisfaction.
Current available CAE method using general modelling practices,
though robust, offers a good scope to model critical details that
have a definite bearing on prediction of its durability. In this
work, an attempt has been made to capture all details such as
effect of bolt pre-load on the rubber bushes/isolators, actual 3D
model of the rubber bushes/isolators, material property based on
measured load-deflection characteristics of the rubber
bushes/isolators & contact interactions of mating surfaces that
were apparently missing in the existing method. All such modelling
enhancements were incorporated in the model, which was solved using
non-linear solution technique. Different set of CAE results of
modal, frequency response, harmonic fatigue, etc., analyses now
correlate better with physical test results in terms of fatigue
life as well as failure location for both failed and passed
designs. This has resulted into not only capturing the physics of
the system more accurately, but also better life/durability
prediction that will eventually reduce the development time of such
exhaust systems through minimal physical testing of prototypes.
Anupam Singh Solanki, Yogesh R. Jaju
Tata Technologies, Ltd.
Symposium on International Automotive Technology 2019