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Automotive Structural Durability and Fatigue Testing

Stringent physical durability is a key parameter of high-quality product designs. It needs to be validated by dedicated physical test setups focusing on structural durability, maximum load, fatigue, and overall lifetime. All measurement and testing data needs to be analysed and correlated to simulation.

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illustration of a car during physical durability testing

Extreme Conditions Durability

Structural durability and fatigue testing is highly significant for a vehicle’s life expectancy. This involves assessing the integrity of critical components such as the body construction, chassis, damping systems, axles, powertrain mounts, and other assemblies. A key focus is understanding how various environmental conditions — like temperature, humidity, and and sunlight — affect the vehicle’s structural integrity.

illu-application-material-properties-testing 01 isolated
  • Optimal weight and dimensioning of the overall construction
  • Safe operation
  • Durability
  • Robustness
  • Performance
  • Reliability

During testing, a vehicle has to withstand typical mechanical loads encountered in operation over a specified simulated lifetime. Failure in the form of fatigue, incipient cracks or degradation is not acceptable.

Before running real-world field tests in dedicated proving grounds, the validation of a vehicle’s structural integrity is conducted as a full simulation on a PC and as tests in automated test facilities in durability labs. Here, road load data is reproduced by actuators.

Structural Durability Testing: From Lab to Road

A Structural Durability Lab Testing Assessment is one of the last stages before a vehicle prototype can be released onto the market. To create structural test programs covering true market requirements, hydraulic, pneumatic and electric actuators, vibration tables and climatic chambers are used.

An operation profile defines the conditions to be monitored but also the target damages of the accelerated testing. In the lab, mainly strain and force-based measurements are used to characterise loads under replayed real-world operating conditions and calculate resulting accumulated fatigue damage.

 

To authentically imitate the road in numerous types of dynamic and static tests, different loads applied to the system under test are reproduced:

  • Multi-axis, full-scale, 4-poster road simulation, covering six degrees of freedom
  • Vehicle stress and strain analysis
  • Biaxial, axial-torsional, multi-axis load machines
  • High-cycle and low-cycle fatigue
  • Thermo-mechanical fatigue
  • Fracture mechanics
  • Crack propagation and growth studies
  • Fracture toughness, high strain rate, quasi-static, stress-relaxation
  • Steering system validation and static strength, torsion, bending
  • Ultimate strength testing

In Road Load Data Acquisition (RLDA), the vehicle is equipped with additional sensors: Strain gauges (SG), acceleration sensors, string potentiometers, special measuring wheels on one or two axes for force and torque measurement, GNSS/GPS/IMU sensors for position and kinematics, as well as video cameras for recording the driving situation.

Teaser

Structural durability lab test

One of the last stages before a vehicle prototype will be released is an intensive test program of the full-scale vehicle, body in white (BiW), chassis, axles, damping and other major parts in assessing the durability design targets ensuring quality, reliability, minimizing future warranty costs. 

The Perfect Setup improving your Structural Durability Validation Workflow

Get the complete toolset in place – from lifetime fatigue analysis based on FE models to measurement and data acquisition perfectly suiting mobile in-field, lab and bench testing, to powerful software for desktop and server for analyzing your data from real-world physics and correlating with simulation. All with the goal that your whole team gets a rapid workflow from design towards sign off.

Benefits Using HBK for Structural Integrity

Orchestrate and accelerate your validation workflow – simulation and physical testing (measurement in field, lab and bench). Focus on your validation data flow, simplify steps and de-risk your project.

The HBK structural durability toolbox allows you to…

 

  • Dramatically reduce time and resources, working with the experts from HBK and a seamless tool chain
  • CAE and FE-based fatigue analysis and simulation with DesignLife
  • Broad portfolio of electrical strain gauges with short delivery times, including pre-wired gauges for immediate use
  • Complete measurement chain from strain gauges, data acquisition systems to software and result , with all elements working perfectly together
  • Data acquisition system input schematics with highest immunity against electromagnetic interference and thermal drift due to patented technology like carrier frequency and auto-cal-routines, galvanic isolation (channel-2-channel, to power, to ground, to network)
  • Bridge measurement technology compensating cable lengths
  • Same data acquisition system for Road Load Data Acquisition (RLDA) and bench testing – from “road to rig”
  • Real-time integration into MTS-329 road simulator test rigs and FlexTest or RPC Pro and into MAST but also to INSTRON 4-posters or component test stands using LabSite software
  • Complete software solution ready-to-start without any programming including post-processing towards report
  • High performance and automated data analysis only software with GlyphWorks
  • Overall data management and collaboration using Aqira
  • Material testing and evaluation as a service or HBK DAQ system that perfectly integrates into ZWICK Röll, MTS, INSTRON

 

HBK System Openness


Integrate the best fit hardware combinations from different vendors in your overall testing solution with technologies such as EtherCAT, PROFINET, ASAM XCP-on-Ethernet or a simple API:

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