K tec 1243 tail load development-fatigue-optimization nafems 2016
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Transcript of K tec 1243 tail load development-fatigue-optimization nafems 2016
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1243 ADT Scraper Tail
Validation ProjectCynde Murphy/Wayne TannerAdaptive Corp.
June 2016
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K-Tec History• K-Tec started in 2000, when Ken Remple built his
first pull-type scraper in his barn, due to frustration with lack of quality pull-type scrapers on the market
• Today the manufacture over 100 vehicles per year
• Sizes range from 25 to 63 yard capacity
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About Adaptive Corporation
Connecting Virtual Design to the Physical World
Innovate
Refine
Validate
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Areas of ExpertisePLM/CAD Quality/
MetrologySimulation
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1243 ADT Scraper in Action…
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1243 ADT Design• New Concept to allow
large design to assemble into shipping container
• Design sized using max/worst case static loading
• Final design approximately 20% over target weight
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1243 ADT ScraperTo begin optimizing the vehicle, we need to understand …
Time history loading of their system in operation
Representative duty cycle of their systemFatigue life of their system (welded
structure)Where they can optimally minimize weight
and cost of their systemGoal of 20%+ Weight Savings
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1243 ADT Scraper Tail
C-Frame
BowlTail
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Project Goals: • Create FEM of Tail System• Determine Load Time Histories on System via Measured Data
• Develop Duty Cycle from Load Time Histories• Calculate Fatigue Life based on Duty Cycle/Load Time Histories
• Perform Optimization Based on Load Time Histories
True-Load
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Create FEM of Tail System
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Create FEM of Tail SystemApply Unit Loads (100 lb) at Loaded Interfaces
Axle LH: FX,FY,FZ
Low Pin: FX,FY,FZAxle RH: FX, FY, FZ
Push Block: FX, FY, FZ
Strut LHStrut RH
Eject Cyl: FX Hitch Pin: FX
Top Pin: FX,FY,FZ
FEA Unit Loads
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The True-Load™ WorkflowFEA Unit
LoadsVirtual Gauge
PlacementTrue-Load/Pre-
Test
Strain Measureme
nt
Loading from Strains
True-Load/Post-Test
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Linear Systems and LoadsLoads
Displacements
Strains Are Proportional to
Are Proportional toAre
Proport
ional
to
Linear
In other words
and
F, Load vectorK, Stiffness matrix, Strain matrixC, Correlation Matrix
Forces from strains𝐹=𝜀𝐶
From Test
From FEA
True-Load
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T-L Pre-test * identify strain gage placement based on FEA Unit Loads
Virtual Gauge Placement
True-Load/Pre-Test
True-Load
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Strain gage Data Collection… on various terrains, roads and duty cycles
Strain Measureme
nt
True-Load
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T-L Post-Test: • Calculate Loads from strain measurement
Loading from Strains
True-Load/Post-Test
Unit Loads
Event 2 Push Load with D8 FullTrue-Load
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T-L Post-Test: • Unit Loads of Fully loaded system vs Weight on Rear Axle of Fully loaded system
Loading from Strains
True-Load/Post-Test
Static Load (Full Pay Load)
70,641 lbs Load Wt Only (rear)
Event 2 Push Load with D8 Full True-Load
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T-L Post-TestLoading from
StrainsTrue-Load/Post-
Test
Total Vertical Load at Axle: 33420 lbs (~5.3% from Estimate Pay Load value of 35321 lbs)
This also demonstrates that the FEM Unit Load can simulate the Fully Loaded condition
Strain Gage Sim vs
Measured Cross-PlotTrue-Load
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T-L Post-TestLoad Time History: Event 5: Haul across woops straight
Loading from Strains
True-Load/Post-Test
True-Load
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T-L Post-TestLoad Time History: Event 11: Haul High Speed Empty on Rough Haul Road
Loading from Strains
True-Load/Post-Test
True-Load
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• Based on input from customer• 1 duty cycle = 1.07 hours of
operation• Direct fe-safe interface
True-Load
Duty Cycle Development
1x
2x
4x
1x
2x
1x
1x
2x
1x
1x
1x
1x
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Fatigue Life CalculationsDatasets = Unit Load ABAQUS Results file (*.odb)
Fatigue Loading = Repeats of Events in Duty Cycle (*.ldf)• 1 Elastic block per road event (there are 12)• Duty Cycle:
Each elastic block/road event is repeated accordingly to create Duty CycleEach block includes datasets (unit loads) from 19 unit loadsEach block Datasets (unit loads*) are scaled according to T-L
*Unit Time HistoriesEntire Duty Cycle= 1.1 hours of operation
1x
2x
4x
1x
2x
1x
1x
2x
1x
1x
1x
1x
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Fatigue Life CalculationsVerity and A36 Parent Material
• Weld geometry was defined in FEM at critical locations• Verity welds defined within fe-safe for fatigue calculations
• Remaining structure defined with A36 fatigue properties
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Fatigue Life Calculations
Identify Low Life Welds
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Next Step…OptimizationLoad Cases:
Highest strain amplitudes in rear of structureUnit loads (static points) – snapshots in time history
Optimization Topology Region
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Optimization LoadsEvent 2: Push Load with D8 Full, t=235.52s
Load
x 1
00 (l
bs)
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Optimization LoadsEvent 5: Haul Across Woops Straight, t=133.438s
Load
x 1
00 (l
bs)
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Optimization LoadsEvent 6: Haul Across Alternating Woops, t=82.794
Load
x 1
00 (l
bs)
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Optimization CriteriaDesign Envelope created
• Interface to applied load must remain• Interface to rest of Tail structure must remain
Objective – maximize stiffnessConstraints – design region volume remaining <= 40%Geometry conditions
• left/right planar symmetry• 2 halves with casting pull direction pull away from middle (prevent vertical wall in middle of structure)
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Optimization Results
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Roller Optimization• 36% Weight Reduction
in rear roller• Confidence in
optimization due to accurate load measurements
CAD weight: 272 lbs
CAD weight: 428 lbs
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Questions?