Fatigue Design and Evaluation Committee 

MTS Systems Corp. Minneapolis, MN

Host: Kelly Donaldson

Disclaimer: These are not the official minutes. They are just one individual's notes

Dates and the location of the next meeting: April 19-21, 1999 in Detroit Area (Auburn Hills). The meeting will be hosted by of Tony Barr, DAIMLERCHRYSLER.

Tuesday, October 20, 1998

Main Committee Meeting: Tom Cordes called the meeting to order.

Each of the Division Chairman reviewed their agenda.

John Hakula

Structural Analysis

Christoph Leser

Road Load Data

Chin-Chan Chu

Fatigue Life Predication

Ed Lu

Materials Property

Raj Thakkar

Component Testing

Jack Champaigne

Surface Enhancement

Russ Chernonkoff indicated that he and John Bonnen will chair a full day session at the 1999 congress.

Tom Cordes reported that AE14++ on multi-axial fatigue is moving forward. Most papers were in and had been reviewed. They are being put into the same format.

Ralph Stevens reported that the 28th annual SAE Short Course on Fatigue will be held August 1999. It will be held in Troy MI.

Henry Fuchs Student Travel Award Presentation:

The winner of this meeting's Henry Fuchs travel award was Ed Rejda, Dept of Mechanical Engineering, University of Illinois. His presentation was t Durability of Plasma-Sprayed Thermal Barrier Coatingv. The unique sample design and testing was discussed. The coating has good thermo-properties, but the mechanical properties are not as good. The coating has a very low fatigue resistance in tension.

A Multi-Phase Project to Evaluate/Develop Structural Durability Digital Simulation Techniques Using an All Terrain Vehicle (ATV) Darrell Socie

Darrell Socie discussed where the ATV fits into SAE FD&E and how it is a natural progression of the programs that FD&E have had over the last 20 years. He pointed out that in 1975 the Keyhole Program was started. It was a 1-D problem. Some problems were worked out and they showed how well the models worked. In 1985, the SAE Shaft program started. This was a 2-D problem, the soft and induction hardened shafts were much harder to analyze than the Keyhole. A lot of tests, analysis, and validation went into that program. The Welded Space Frame Problem or ATV is a 3-D problem. The ATV is a cost effective vehicle for FD&E. The goal is to predict what and where it will fail for a given test course. The technical issues that are needed for the project and the project plan were discussed.

Materials Property Division: Ed Lu chaired the Division Meeting. The minutes from the March meeting were approved.

Status of Current Activities:

Composites Task Group Progress - Alan Kallmeyer and Greg Finnes The group is investigating general effects of fatigue. They have found that frequency has little effect, but temperature has a significant effect. They are working on developing a damage temperature model.

Impact Damages of Composites - Peter Kurath & Gavin Horn Working to understand the fatigue process after damage to the structure or sample has occurred. Thus far, samples that were damaged by impacts have longer lives than the baseline.

Presentations:

Effect of Shot Peening Parameters on Fatigue Life Peter Bailey & Jack Champaigne General discussion of shot peening. The dimple depth is about equal to the diameter, and generally deeper depth results from smaller shot. One of the biggest uses of shot peening is to improve the residual stresses from machining.

Effect of Shot Peening Coverage on the Fatigue Life of Steel and Aluminum Phil Dindinger

Data was presented on tests of steel and aluminum peened and non-peened samples. For the steel samples, the peened samples had about the same lives as the non-peened, and in some cases shorter lives. The aluminum data was presented for Russ Chernenkoff. The shot peened aluminum samples had longer fatigue lives than the non-peened samples. Most people expected only small differences.

Structural Analysis Division: John Hakula chaired the Division Meeting. The minutes from the March meeting were approved.

Presentations:

Cyclic Stress Analysis of Notched Members with Application of A New Plasticity Model - Yanyao Jiang and Biqiang Xu - University of Nevada, Reno. A new plasticity model was presented. Using ABAQUS, the user can input materials properties. In the tension-

torsion case, the new model predicts the stress strain response better than most other models, and the new model predicts much better than others for notched components.

UIUC Spring Semester FEA Project Results - Dan Klann Discussed analytical model of the ATV to predict the high stress location(s) with vertical and horizontal loads as applied in the U of I static rig. Model did not accurately predict the stresses because the boundary conditions chosen by the students were not as good as they could have been.

Component Testing Division: Paul Lubinski chaired the Division

Meeting for Raj Thakkar. The minutes from the March meeting were approved.

Status of Current Activities Since Last Meeting:

Digital Prototype for Durability Task Group Activity Update On Monday (previous day), a task group meeting was held for all the people working on the digital prototype project. Several people briefly reviewed the information presented the previous day.

Fatigue Editing Drive Shaft Data for Accelerating Simulation Tests Using a Wang-Brown Multiaxial Fatigue Life Prediction Approach - Wissam (Sam) El-Ratal

The first step in the process is to edit the data in the normal manner with filters and remove any spikes in the data. The history is then edited by this technique. For the example shown, the test time was reduced by about 1/3 or from 31 days to 10 days.

Comparison of Experimental and Analytical Loads and Accelerations of an ATV Moving Over an Obstacle Course - Cameron Nelson and Dick Kading:

Using the data from the U of Illinois students riding over DarrellFs test course, a DADFs model of the ATV going over the track was constructed. Only a few parts have been analyzed. Thus far, the test data and the model results match from a qualitative standpoint, but the quantitative results do not match well.

Fatigue Life Prediction Division: Chin-Chan Chu chaired the Division Meeting. The minutes from the March meeting were approved.

Presentations

FD&E Public Software ----A Proposal by A. Conle, Ford

Al suggested that FD&E checkout or test fatigue analysis software and make it available to the general public. It would be available on the FD&E web site. The software would have a GNU general public license. Various aspects, both pro and con, of the subject were discussed.

"Implementation and Verification of a Multiaxial Rainflow (Wang-Brown) Counting Algorithm" Vladimir Ogarevic

The Wang-Brown model and how multi-axial counting works were described.

With this model, torsional data is needed to get close agreement. Some examples of life predictions were presented. Some results indicated that the Fatemi-Socie damage model gave better results.

Road Load Data Acquisition Division: Christoph Leser chaired the Division Meeting. The minutes from the March meeting were approved.

Presentations

Spinning Wheel Intergated Force Transducer Design - Jodi Sommerfeld, MTS Systems

The new transducer was described. The transducer is for cars and light trucks. The output is data of three forces and three moments at the wheel. The specifications and limits were described.

Surface Enhancement Division: Jack Champaigne chaired the Division Meeting. The Minutes of Last Meeting were approved.

Current Activities

J443 - Announcement regarding acceptance of last revision to J443 Procedure for Using Standard Test Strip

J2277 - Shot Peening Coverage, report by Dave Francis

Almen Strip Performance Comparisons - A Ahmad

J2441 Shot Peening - Report by Dave Hale

Aluminum Peening Coverage Task Force - Report by Jack Champaigne

Computer Generated Almen Strip Saturation Curve - Report by Jack Champaigne

Announcement of ICSP-7 in Warsaw, Poland - by Jack Champaigne

Interaction by Surface Enhancement with other FD&E Divisions - by Jack Champaigne

Wednesday, October 21 -Technical Session

"Fracture Testing of Soft Biological Tissues" Dr. Doug Adams, University of Minnesota

Discussion of research on soft tissues such as cartilage which is mostly water and about 1-2 mm thick. He discussed the use of various tests including scratch tests and fracture mechanics tests such as the J Integral. Large variations in the results have been found. His research is leading to the repair and /or replacement of damaged tissues.

"Fatigue and Fracture: Applications in Biomechanics" Dr. Patricia Neale, Mayo Foundation, Rochester, MN.

Discussed the testing of artificial finger joints. Tests include fatigue and wear; fatigue tests use servohydraulic equipment in very similar ways metals are tested. In addition, studies of the elbow joint were discussed. Most elbow problems are from baseball pitching. Research could lead to when to stop pitching, and how to rehab.

"Static and Fatigue Testing of Spinal Implants" - Dr. Steve Griffith & Dr. Jennifer Pavlovic, Spine Tech, Inc. Minneapolis,MN The spine and how the disks are repaired were described in some detail,. The studies indicate that the repaired disk is much stiffer that a normal disk. Some ASTM standards have recently been issued on disk repair.

"Durability of Polymer Surfaces in the Auto Industry" Dr. Vincent Jaradet, MTS Innovation Center, Oakridge,TN

Discussion of how paints are tested with nano indentations and scratch tests. Some types of scratches heal with time and temperature, some do not. These tests provide a quantitative evaluation of different surface paints, and coatings. These tests all could lead to fewer complaints about the painted and coated surfaces.

"Prediction of Microstructure Evolution, Residual Stresses, and Hardness Distribution Induced by Welding Processes" Dr. Victor Li, Battelle Labs, Columbus, OH

Discussed that several codes were available to predict the residual stresses and distortion in welds. Analysis of a spot weld was discussed. The first step in the prediction of strength, is the microstructure and then the hardness. Predictions for the strength of a lap shear joint were close to the actual. When multiple spot welds are close to each other, the analysis is significantly more difficult.

Effective Road Profiles for Fatigue Durability Testing" Dave Fricke, MTS Systems Corp., Eden Prairie, MN

Using this, the road profile is simulated instead of the vehicle response. This also provides a good method to determine a tire model.

"Knowledge Based Engineering-Issues and Challenges" Dr. Tom A Johnson, General Motors Truck & Bus Group, Milford, MI. Within large companies, few groups understand what knowledge is contained within. To understand, you must listen to all levels. Building a knowledge based organization starts at the top, starting with creating focus, determining what technologies are needed, and making and running a plan. Various aspects of this were discussed ,and how this new process was applied in a drive line and sound quality problem.

Afternoon Wednesday March 12, 1997

Divisional Planning Sessions were held concurrently in Two rooms. The future work efforts of these five Divisions will be coordinated by the chairman and the task group leaders of the respective divisions. Please contact the chairman with any questions or needs. Documentation of future work planned will be included in the full minutes to be distributed before the next meeting.

Future Meeting Schedule:

April 20-21,1999in Detroit, MI, Tony Barr (Chrysler)

October 18, 19 & 20 1999 in Lafayette IN, Jack Champaigne (Purdue University)

Spring 2000 in Waterloo, IA, Ray Thompson

Fall 2000in Toledo, OH, Ali Fatemi (University of Toledo)

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SAE Fatigue Design and Evaluation Committee Meeting

Structural Analysis Division Unconfirmed Minutes

Minneapolis MN (October 19 -21, 1998)

Tuesday, October 20, 1998 { Divisional Progress Meeting

1. Approved March 1998 Structural Analysis Division Minutes

2. Cyclic Stress Analysis of Notched Members with Application of a New Plasticity Model, Yanyao Jiang and Biqiang Xu { University of Nevada, Reno Nevada

Yanyao Jiang presented some results from the stress analysis of notched members under cyclic loading. He implemented a new cyclic plasticity model into the finite element code. The plasticity model adopted is characterized by its ability to accurately describe cyclic deformation and stress relaxation. With the implementation of the new plasticity model into the finite element code, the changes of the stress and strain distributions with increasing number of loading cycles were adequately captured for a notched shaft. The model greatly improves the accuracy of the elastic-plastic cyclic stress analysis, thus improving the fatigue life predictions of the notched members.

3. UIUC Spring Semester FEA Project Results, Dan Klann { John Deere Dan Klann reported on the senior design project completed in the spring at the University of Illinois (tAnalytical Model of an All-Terrain Vehicle Framev, ME and IE 280, Team P-20). DanFs presentation is attached. The student report is available in electronic form (11.1 Mbytes .zip file of Microsoft and .jpg formats. Most of the files are report figures that had to be scanned). Their Patran model database is also available. The students did a very good job of measuring by hand most of the geometry they used, and also in creating a FEA mesh. The students attempted several variations of boundary conditions to represent a test rig built by another student team. The students recognized that their final attempt needed further refinement. Dan noticed in the deformed shape plots that the knuckle housing changes orientation relative to the control arms, and he thought this motion looked suspicious. See the attached deformed shape plots. The studentFs work helped high light a number of details that will need to be considered in future modeling. DanFs presentation identifies some of those details. Dan also noted a number of lessons learned. Since the spring project, much progress has been made in developing a better definition of the geometry and FE mesh. That work is reported elsewhere by Dan and others.

4. ATV Geometry Status, Dan Klann { John Deere

See attached slides.

Wednesday, October 21, 1998 { Divisional Planning Session

Attending: Hari Agrawal, Zhengxian Baj, James Burg (Alcoa), John Hakala, Yanyao Jiang, Dan Klann, Ric Leist, Jin Qian, Andrew Whelan, Michele Wegscheid

Dan Klann reviewed possible suspension component FEA models of interest, including:

Upper control arms

Lower control arms

Rear suspension brackets

Dan is compiling a notebook of the IGES files, sketches, and photographs of the ATV that will be available for reference on a web site. Contents include IGES suspension model, Hypermesh models, UIUC data summary, Patran conversions, five sets of photographs, DADS model, and the spring term UIUC work.

Ric Leist would like to participate. HeFs interested in locating the sensitive areas of the structure, and predicting the areas with the highest fatigue damage. Which is better? A shotgun approach where the fatigue code analyzes the complete structure, or a localized approach that identifies and analyzes the hot areas. What can we correlate? Can we apply single loads on the frame and predict high stress areas. Will FEA predict correct locations? Are there models to exchange? Universities are using ANYS, and NASTRAN is a common FEA data format that can be readily translated.

Andrew Whelan is interested in doing a modal analysis of the frame and suspension components and correlating the static stiffness, displacements, and modal results with test results.

John Hakala will contact Ric Leist, Jin Qian, H. Agrawal, J. Burg, M. Wegscheid, and Zhengxian Bai for possible reports on structural analysis on the above topics for the April 1999 meeting in Auburn Hills.

Respectfully submitted by: John Hakala { SAE FD&E Structural Analysis Division Chairperson

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SAE Fatigue Design and Evaluation Committee Fatigue Life Prediction Division

Unconfirmed Minutes

Minneapolis, MN (October 19-21, 1998)

Tuesday, April 20, 1998 { Divisional Progress Meeting

Web Based Fatigue Calculations - Al Conle

Al noted that most users of fatigue software are using just a few commercial packages, and those packages are becoming quite robust. Therefore, users are less likely to develop, program, and share their own methods. These methods might be new ideas or automation of simple or repetitive engineering tasks. Al suggested we might be able to collect user-written software and make the source and documentation available as a committee project.

Examples that Al showed included bearing life calculations, transmission shaft calculations, spot weld fatigue analysis, and RPC formatting and data processing tools. One method for making the software available is GNU

Licensing, a means for registering freeware and distributing it to others. Al will contribute some of his examples to get the sharing process going. Professor Socie said there is a six-university consortium (Agile Manufacturing Engineering Center?) that has done what Al is suggesting. The university team was surprised by the success they achieved.

Implementation and Verification of a Multiaxial Rainflow (Wang-Brown) Counting Algorithm - Vladimir Ogarevic Vladimir briefly reviewed rainflow-counting methods. In uniaxial methods, the objective is to identify closed hysteresis loops. In multiaxial methods, the objective is to count reversal points that define equivalent hysteresis loops that are not necessarily closed. Vladimir presented one multiaxial method. He also discussed the Wang-Brown damage parameter, which is based on the maximum shear strain. Vladimir noted that using theoretically correct values for material constants in damage equations can lead to significant errors. Multiaxial fatigue life models require torsional test data to perform well. Professors Socie and Kurath both said that material constants do depend on loading conditions and are not truly constant. Researchers usually pick a narrow range for their tests, and fail to realize the constants' dependence on loading conditions.

Wednesday, April 21, 1998 { Divisional Planning Session

On the page, Tim has collected experimental data from several sources. C.C. Chu noted that she has foundthat some of the data files appear to be partially or totally corrupted. Tim will investigate. John Deere has provided funding for some of Tim's Ph.D. thesis work, and Deere will consider making more of Tim's work

available on the committee web site. Since Tim is nearing graduation, Tim's page is being transferred to Christoph Leser. The page will be the primary home page for the FDE ATV project. C.C. Chu suggested the committee consider the sensitivity of life predictions with respect to material variability in performing life

predictions for the ATV project, when the need for those calculations develops. She suggested that committee members may have a number of favorite fits for the materials data, or perhaps an upper and lower bound

fit.

Respectfully submitted by: Chin-Chan Chu { SAE FD&E Fatigue Life Prediction Division Chairperson

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SAE Fatigue Design and Evaluation Committee

Component Test Division

Unconfirmed Minutes

Minneapolis, MN (October 19 { 21, 1998)

Tuesday, October 20 { Divisional Progress Meeting

Vice-Chair Paul Lubinski began the meeting at about 1:20 p.m. The minutes from the meeting held March 31, 1998 in Manhattan, KS were approved. Two presentations took place during this meeting.

First, Dick Kading from CADSI gave a presentation on tComparison of Experimental and Analytical Loads and Acceleration of an ATV Moving over an Obstacle Course.v The focus of the presentation was the DADS dynamic modeling in which several U. of Illinois students have been involved. Correlation results were presented for several system characteristics, including modal frequencies, reaction forces, and accelerations. Much attention was paid to the parameters of tire modeling. The results presented here did not show as good a correlation for acceleration as desired, but it was noted that the correlation has improved since the generation of those results.

Second, Wissam El-Ratal from Visteon gave a presentation on tFatigue Editing Drive Shaft Data for Accelerating Simulation Tests Using Wang-Brown Multiaxial Fatigue Life Prediction Approach.v The presentation showed the combined input from servohydraulic actuators and dynamometers used for the test, and discussed the issues of different frequency capabilities of these devices. Sam discussed the steps in selecting locations to place rosettes on the sample part, selecting the rosette type, and analyzing the strain data. The approach to the multiaxial fatigue analysis (including Mroz strain hardening, Glinka rainflow, and Wang-

Brown damage model) was discussed. Special attention was paid to tclosing the gapsv between the drive files used for test construction such that the transitions were within the equipmentFs load/stroke/ frequency capabilities, would not risk damage to the equipment, and would not introduce additional fatigue to the samples.

Copies of the overhead material from these presentations are attached to these minutes to provide further detail.

Wednesday, October 21 { Divisional Planning Meeting

Vice-Chair Paul Lubinski began the meeting at about 1:30 p.m. During MondayFs Digital Prototype for Durability special meeting, several people volunteered to help out with action items required for the near future. Other ideas, items, and volunteers came forward during this planning meeting. The following is a summary of all those items and volunteers.

Action Volunteer(s)

Assistance/further work on UIUC finite-element model Zhengxian Bai

Bushing tests Jay Meldrum

Tire tests, possibly also bushing tests Will Mars

Tear down ATV and measure mass/inertial properties Defiance (Charlie Stanton)

Modal testing after completion of teardown Andrew Whelan/Jay Meldrum

Action Volunteer(s)

Static stiffness (frame by itself, and frame with powertrain) No volunteer as of 10/21

meeting; seeking one ASAP

Continued work on UIUCFs DADS model Dick Kading

Continued work on U. of ToledoFs ADAMS model Ric Mousseau/UT faculty

Procuring additional control arms Requester(s) to contact

Rockford Products and/or

Honda dealer

Procuring additional shocks Paul Lubinski to contact

Arvin Ride Control

Spectral analysis of UIUCFs existing load histories Darrell Socie/UIUC

Material analysis when first fdestroyedF frame Tom Cordes/Al Conle

becomes available

Ten frames and additional transducers (see funding item)

Additional funding Tom Cordes & Darrell Socie

to make formal proposal to Deere & MTS (possibly also Ford?)

It is assumed that the requesters of the actions will be in contact with their volunteers as soon as possible to work out the appropriate details. If there is any question about the action items, please contact Raj Thakkar or Paul Lubinski as soon as possible.

Respectfully submitted by: Raj Thakkar and Paul Lubinski { Chairperson and Vice-Chairperson of the SAE FD&E Component Test Division.

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SAE Fatigue Design and Evaluation Committee Material Property Division

Unconfirmed Minutes

Minneapolis, MN (October 19-21, 1998)

Tuesday, October 20 - Divisional Progress Meeting

1. The minutes from the March meeting in Kansas were approved as written.

2. Status of Current Activities

- Composites Task Group Progress Report I- Greg Finnes reviewed the studies of the frequency effects on the fatigue of the thermoplastic composites. The objectives are to determine the general fatigue characteristics and explore the temperature/frequency/energy effects on the fatigue life. Test results and future research plan were presented. (Attachment #1)

- Composites Task Group Progress Report II- Gavin Horn from UIUC presented tQuantifying Impact Damages in Polymer Composites Using TSA.v (Attachment #2)

3. Presentations

- Discussion on the Shot Peening Parameters { Peter Bailey (Attachment #3, SHPpara.ppt)

- Preliminary Test Results of Peened and Unpeened 1045 steel and 2014-T6 aluminum { Phil Dindinger

Wednesday, October 21 - Divisional Planning Meeting

1. Current Activities

- Composite Materials Group - Greg and Alan will continue the work on the frequency, temperature, and stress amplitude effects on the fatigue strength of thermoplastic composites. The project reaches a critical juncture and a new group leader is needed. Alan Kallmeyer is willing to serve. Tom will contact Mohamad El Zein to see if he still wants to take the responsibility. New material candidates include polymer, woven fibers, and rubber.

- Powder Metal Group - Ralph Stephens will

- Continue the project on the high cycle fatigue region. Tom Cordes suggested if the mean stress effect

Could be explained by the crack propagation data.

2. New Business

- Shot Peening

1) The use of axial fatigue samples was questioned since many believed that the crack would initiate at subsurface. Some believed that a bending load should be used. Tom Cordes and Phil will use SEM to examine the origin. Russ may have done that already.

2) The residual stress of the bare/polished 1045 steel was questioned. Tom Cordes will help to assess the residual stress of the bare 1045 specimens. (Phil: Could you send one 1045 steel bar to Tom?)

3) Ric Leist from Cessna observed significant difference in fatigue life from peened and unpeened axial fatigue samples

4) Sulfuric anodizing degrades fatigue life of 2014-T6 aluminum. Shot peening effect should be evident even on the axial specimen. Ed Lu can prepare samples if needed.

5) Additional tests of 2014-T6 are being performed. Ed will check with Russ to see if he would continue the tests and make a presentation on shot peening and fatigue life in the next meeting?)

6) Professor Jack Soules has provided a report on the residual stress assessment using the Eddy current technique. A copy of the report is being reviewed. (We may be able to invite him to present the result in the next meeting.)

- AISI Material Properties Development - Ali Fatemi will discuss the correlation and estimation of material constants.

- ATV Materials - Tom Cordes of Deere will perform the failure analysis of components being tested at Darrell SocieFs laboratory at UIUC.

Attachment #1

"Composites" presented by Greg Finnes at North Dakota State University.

Attachment #2

tQuantifying Impact Damages in Polymer Composites Using TSAv presented by Gavin Horn at UIUC.

Attachment #3

"Shot Peening Parameters" presentation by Peter Bailey at Electronics Incorporated, Inc. (SHPpara.ppt)

Respectfully submitted by: Ed Lu { SAE FD&E Material Property Division Chairperson

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SAE Fatigue Design and Evaluation Committee Meeting

Road Load Data Division

Unconfirmed Minutes

Minneapolis, MN (October 19-21, 1998)

Tuesday, October 20 - Divisional Progress Meeting

1. Christoph Leser moderated the meeting.

2. Deferred discussion of the Rainflow Format Standard and the Time History Standard status to the planning session.

3. David Salmon, from MTS, gave a talk on tSpinning Wheel Integrated Force Transducerv. He discussed some of the design considerations including weight and durability of the transducer. The transducer fits between a reclaimed hub and wheel and can fit on passenger vehicles. The transducer measures the 3 forces and 3 moments going into the vehicle from the tire.

Wednesday, October 21 Divisional Planning Meeting

Christoph Leser chaired the meeting. The minutes from the previous meeting were approved.

Rainflow standard { No progress was made since the last meeting.

Time history format - Andrew Whelan has plans to send out a request (survey) for receiving comments on the need for a time history format standard. There was discussion amongst the group that there may not be a need for a standard format for time histories. One thought was that if the FD&E group can share time histories through the ATV project without problems, there may not be a great need in the industry for a time history format standard. Also, various topen formatsv, with reasonable acceptance in the industry, already exist.

Statistical analysis of data { Darrell Socie presented work from Jason RothFs (former grad student) thesis on predicting future loads based on existing loads. Darrell gave a couple of examples of how the prediction process works with multi-pass data and multi-operator data. This process assumes the application or operation is similar. Darrell is interested in receiving load history examples from industry to try out the process. Darrell will make Jason's thesis available to Christoph Leser from whom other committee member can receive copies.

Christoph Leser will check with Virginia Tech on the work they were doing with statistical analysis of data.

ATV Contributions:

A channels list was provided by Darrell Socie. This list is what is used at the UIUC for student projects. The list includes front and rear suspension characteristics.

Some discussion about the need to instrument and measure the loads generated by the operator was conducted. These would include the seat, handle bars and foot pegs. Zhengxian Bai will investigate doing this.

A discussion about collecting load histories from other applications (besides the plywood course) was conducted. This could include ski slopes and trails in woods. The recommendation was not to collect additional load histories at this time. The effort of the group should concentrate on correlation the existing loads to digital models, not in trying to understand the customer use of an ATV.

New Business:

None

The meeting was adjourned.

Respectfully submitted by: Ray Thompson { SAE FD&E Road Load Data Division Vice-Chairperson --------------------------------------------------------------------------------------------------------------

SAE Fatigue Design and Evaluation Committee Surface Enhancement Division

Unconfirmed Minutes

Minneapolis, MN (October 19-21, 1998)

Last Minutes - Comments Paul Trotta -(Hope Supply) reported that he sent out an addendum to the last meeting minutes.

Document Distribution

It was decided to use email for distributing documents for comments/review. Adobe Acrobat would be used for formatting/viewing documents. Electronic documents will be tread onlyv so comments can be sent via email, fax, or mail.

Dave Francis will test the system when he sends out trial document SAE J2277.

Agenda Items

SAE J443 - D. Francis (Procedure for Using Standard Shot Peening Test Strips)

J. Bernabe noted that paragraph #5 did not specify exactly how to compensate for pre-peen out of flatness. After some discussion, a motion was made by D. Hale not to modify the specification and was seconded.

The specification had enough votes for approval.

SAE J2277 Briefly discussed; to be sent out for review via email

Discussion of Almen Strip Performance Comparison

J. Champaigne presented data collected by A. Ahmad

4 different types of Almen strips demonstrated slightly different responses to shot peening. Residual stress and surface finish were also measured.

Exact cause for the difference response is unknown; it is suspected that the difference is related to residual stress.

The initial investigation team was comprised of J. Champaigne, A. Ahmad, P. Trotta, and J. Whelan. Other members requesting to be part of the team were: J. Bernabe, D. Francis, P. Bailey, D. Hale.

A. Ahmad to present the data at the next meeting.

J2441 - Shot Peening (D. Hale)

Changes to the proposed document were reviewed.

Corrections to be made and distributed by email.

Aluminum Almen Strips

Study underway; results to be presented next meeting (J. Champaigne).

Computer Generated Saturation Curves

Short discussion on various programs.

More work to be done on comparing different programs; no action items.

ICSP-7 Poland

Presently only 35 abstracts; more are needed.

Miscellaneous

J. Champaigne felt we should spend more time in the main Fatigue, Design, and Evaluation

meeting. He felt there was little tshot peeningv representation in that meeting. He also felt it would be useful to the Surface Enhancement sub-committee to listen to FD&E presentations. Few attendees seemed to share his position.

Respectfully submitted by: Dennis Scharer for the SAE FD&E Surface Enhancement Division.

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SAE Fatigue Design and Evaluation Committee

ATV Digital Prototype for Structural Durability Task Group

Unconfirmed Minutes

Minneapolis, MN (October 20 { 21, 1998)

Monday, October 19 { Task Group Meeting

Raj Thakkar called the meeting to order at 1:00 p.m.

The minutes from the special meeting held March 30, 1998 in Manhattan, KS were approved.

Raj reminded all in attendance to be sure to have a copy of the project plan that he and Charlie Sieck had formulated since the last meeting.

The meeting then proceeded with presentations by those involved in the various tasks of the project. The presentersF notes will be attached to these minutes. The following is a summary of those presentations.

Darrell Socie outlined a project plan consisting of four phases: subsystem characterization, structural system characterization, full vehicle characterization, and accounting for real-world variability. DarrellFs assessment of capabilities for completing these phases is that Phase 1 can be completed with established tools, Phase 2 requires better integration of established tools, Phase 3 can be accomplished with emerging tools, and Phase 4 requires all new tools. The estimated time line shows up to 10 years for completing the entire project. Darrell made a similar presentation at an SAE TOPTEC earlier in the month.

Dan Klann summarized the reverse engineering and FE model-building activities. Dan started by thanking all those who contributed time and financing for this project. He showed a view of the frame model as completed thus far. The suspension is not yet in the model, but the IGES file per CMM data will be the starting point for incorporating the suspension. Dan noted that the documentation on this project now consists of 50+ pages of notes, 140+ photos, and a service manual available for purchase. The September tteardown partyv helped determine a lot of previously missing geometry detail. Issues to resolve yet are bushing & tire characterization, verifying tube thickness, shock/spring free length, and accounting for differences among available frames. Plenty of data on this project can be exchanged (E-mail, FTP, formatting/reformatting, etc.), but that is a largely tself-servev task.

Ed Koranda, Greg Fialek, and Cameron Nelson summarized their work at the U. of Illinois. The three ATV-related projects during the spring semester and summer period were test stand design & construction, dynamic (DADS) modeling, and the frame FE model. Ed discussed the test stand and showed a ~10-minute video. This stand had the frame anchored at the left front suspension, loaded at the right front suspension, and held in the rear such that displacement was fixed but rotation was free. Greg and Cameron discussed the DADS and FE modeling. One slide in their presentation was a tmoviev of the DADS model moving over a track. Loads were extracted from the model. Differences between these loads and actual test loads may have depended on how to account for the driver. There were two FE models: one with shell elements for the tubes, and the other with beam elements for the tubes. Eigenvalue/eigenvector extraction was run on these models under the same boundary conditions as the test. Fall semester projects include more development of the test stand, continuation of test stand flexible-body modeling barely started in the spring and summer, and use of a control arm as a load cell. Project documentation such as results files can be found at the web page of the National Center for Supercomputing Applications (NCSA). Thanks go to Dick Kading, Dan Klann, Peter Kurath, Charlie Sieck, Darrell Socie, and NCSA for their help in these projects.

Kurt Munson summarized the progress on EG&GFs test rig. The rig is using known, repeatable loads. The vehicle on the rig has ballast at the foot pegs, but no driver inputs and no tires. Because field data has not been available, sine waves and random noise vertical inputs are being used for testing. The vehicle is still on the rig, and there is an opportunity to put on more data channels. Kurt showed examples of time histories of acceleration and strain, PSD of displacement, and distribution of principal strain vs. principal strain angle. The goal is to achieve correlation in terms of statistics, time histories, PSDFs, rainflow counts, and damage. Future plans include use of more complex loads and getting more ideas for where & what to instrument.

Ali Fatemi reviewed the quantities and whereabouts of the ATVFs and parts. There are six ATVFs: one each at U. of Toledo, UIUC, Defiance, and EG&G-SK (instrumented vehicle), and two in DarrellFs barn. Additional parts include a frame and control arm at UT, and a control arm at Ford.

Ric Mousseau summarized U. of ToledoFs vehicle dynamic modeling activities. The presentation included a comparison of modal results between hammer excitation and shaker excitation. Craig Meyer has placed shaker test data on a web page. The vehicle shows five rigid body modes <13 Hz. Tasks accomplished during the multi-body modeling project include measurement of masses & CGFs, measurement of tire stiffness, and validation of spring/shock data. The modeling used revolute joints for the bushings, full shock curves, and an assumption of a rigid frame and engine. The next steps are to refine the data sets, update the models, and construct Autosim models. Needed information for model improvement includes bushing rates, front suspension geometry, steering geometry, and frame torsional stiffness.

Benny Rediers discussed the vehicle modal testing performed at Defiance. The tests compared results from excitation at three locations vs. excitation at one. There was no driver mass. Animations were displayed for rigid body modes, global flexible modes, and local flexible modes (e.g. large deflection of handlebars). The next steps for this test activity include aiding correlation of the tire model and full vehicle model, as well as reviewing the project plan to ensure conformity of analysis and test parameters.

Jay Meldrum discussed Keweenaw Research CenterFs (KRCFs) capabilities to help with our project, with emphasis on elastomer testing (e.g. for stiffness and damping). Those capabilities include temperature-

controlled testing and side loading. KRCFs tcalibration tubev results seem to indicate accuracy in the testing to well beyond the frequency range of our interest. Several attendees asked what kinds of testing to perform at KRC and/or volunteered sources to help the modeling activities. Axial, radial, and torsional characteristics of the bushings seem to be agreed upon as needs.

Al Conle led the discussion about web page issues. He noted that Tim LanglaisF data was in the process of being transferred to sites at MTS, the U. of Waterloo, and NCSA. Al recommended against use of a single site for the data of this project, although one central site could perhaps point to all the appropriate individual pages. MTS has a site that can be the central point and offer up to 6 GB. Tom Cordes asked if the committee would need to fund hardware and the hiring of someone to administer a site. Darrell Socie gave an example of a similar condition at UIUC, noting a cost of ~$50K/yr. for a graduate student dedicated to maintaining web site content for his departmentFs senior projects. The group decided to discuss the issues further at that eveningFs executive meeting.

The final topic of the meeting was future planning. Several action items and volunteers thereof came up during this discussion. These details will be listed in the minutes of the October 21st Component Test Division planning meeting, as additional actions and volunteers came forward during that meeting.

The meeting was adjourned at approximately 5:30 p.m.