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Nikkel, Karsten
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document
Formed Thin Sheet Structures-Concepts for Fatigue Life Calculation
Abstract
A fatigue life calculation of formed thin sheet metal structures is best undertaken using local concepts, as principle stresses can often not be defined. Currently linear finite element calculations are the most common method used to determine local loads. Only materials' Young's Modulus is required for the calculation. The calculated stresses are translated into fatigue life estimations using various methods. Non-linear finite element calculations are better suited to describing the local stress-strain states under alternating loads. Knowledge of the cyclic stress-strain curve of the utilised material is required for this procedure. Subsequently the local strain is assessed using the strain-life curve. Forming can have a substantial influence on the cyclic stress-strain curve and the strain-life curve. By running a preliminiary forming simulation, the local material thickness and the local state of forming can be estimated, without having to manufacture a prototype part. A comparison of linear and non-linear calculation concepts for a stiffening sheet for a MacPherson strut unit with experimental results shows that a linear calculation cannot describe the exact location of the highest loads if a constant material thickness and cyclic material data for the base matreial are used for the calculation basis. A non-linear finite element analysis with a preliminary forming simulation including the changes of local sheet thickness as well as the changes of the cyclic material data on the other hand predicts the location of crack initiation accurately. The comparison of the strain-life curves from experiments with those derived from linear and non-linear finite element calculations shows that the prediction accuracy of a fatigue life calculation can be substantially increased for formed sheet metal parts if the local changes of material thickness and cyclic material data due to the manufacturing process are taken into account.