Transient Fatigue Analysis of Exhaust System Mounting Brackets for Commercial Vehicle – Correlation

Paper #:
  • 2017-01-1333

Published:
  • 2017-03-28
Abstract:
In commercial vehicles, exhaust system is normally mounted on frame side members (FSM) using hanger brackets. These exhaust system hanger brackets are tested either as part of full vehicle durability testing or as a subsystem in a rig testing. During initial phases of product development cycle, the hanger brackets are validated for its durability in rig level testing using time domain signals acquired from mule vehicle test data. These signals are then used in uni-axial, bi-axial or tri-axial rig facilities based on their severity and the availability of test rigs. This paper depicts the simulation method employed to replicate the bi-directional rig testing through modal transient finite element analysis (FEA). The FEA analysis is carried out with the inclusion of rubber isolator modeling, meshing guidelines etc. FEA results are in good agreement with rig level test results. This paper also explains a method for identifying root cause for high stresses in critical locations and identification of predominant mode causing failures using FEA. Effective design modifications can be done if root cause is clearly identified. Also, the type of test-rig to be used during physical testing to reveal the possible failures during test can be identified using this procedure. Keywords: FEA, exhaust systems, hanger brackets, modal transient, correlation
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