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Simulation-based lifetime prediction for cables

In modern vehicles, the routing of cables is complex due to narrow design spaces. With alternative drive systems, new components come into the vehicle, often accompanied by new cable routings or completely new cable types. Therefore, there is a lack of experience with those new routings or cables.
In many companies, the simulation of cables with geometrically exact rod models is already well established. Thus, already in the design phase, possible conflicts can be solved. Typical questions are related to the expected cable deformations, the optimal length of the cable, or required mounting positions. Also, one tries to find cable routings which reduce (static and variable) loads in the cable as well as reaction forces and moments at the mounting points.

In this work, we…

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In modern vehicles, the routing of cables is complex due to narrow design spaces. With alternative drive systems, new components come into the vehicle, often accompanied by new cable routings or completely new cable types. Therefore, there is a lack of experience with those new routings or cables.
In many companies, the simulation of cables with geometrically exact rod models is already well established. Thus, already in the design phase, possible conflicts can be solved. Typical questions are related to the expected cable deformations, the optimal length of the cable, or required mounting positions. Also, one tries to find cable routings which reduce (static and variable) loads in the cable as well as reaction forces and moments at the mounting points.

In this work, we want to present and discuss an approach to simulation-based lifetime prediction for cables. Two aspects are considered: (1) the definition of a suitable local load to count load cycles and (2) identifying an SN curve from cable lifetime tests based on this local load, which can be used for damage calculation.

Usually, due to its flexible nature, a cable has no unique installation position and local deformations are not known a priori. Thus, obviously, we need to look at local loads along the cable rather than external loads at the boundaries.
From the simulation, we get forces and moments (i.e., cross-section-integrated quantities) at arbitrary arc length positions. Those are mapped to local stress quantities at the surface of the cable, which shall be used for Rainflow counting and SN curve identification. Well-known candidates are, e.g., local stresses generated via the critical plane approach or local forces pointing in characteristic directions.
Once the local load signals are computed, it is straight forward to apply Rainflow counting to each signal to find triples of load amplitude, mean load and number of load cycles.
Finally, a damage calculation can be performed. With a generic SN curve, only a comparative analysis is possible. To achieve absolute damage calculations, a specific SN curve is required, which represents the correct fatigue behavior of the cable of interest.

Recently, we studied the concept of a cable SN curve. Obviously, such a cable SN curve only is valuable if it is independent of the cable installation, i.e., independent of the cable length, its routing or its mounting position and orientation. Thus, on the one hand, as already mentioned, the suitable definition of the local load is essential. Only if this is appropriate, we have a chance to find the desired cable SN curve. On the other hand, several tests with different local deformations must be considered to establish a sufficient database covering the most important local stress states, which cause the fatigue failure.
The interesting question is, if – by the appropriate selection of the local stress quantity – a common SN curve can be found for the fatigue data from all tests. This idea has some similarities with the well-known RxMS approach for establishing SN curves for welding points.

In the real tests, we observe a possible failure by monitoring the electrical resistance. But measuring local loads along the cable during the experiment is very difficult or simply impossible. Therefore, we also simulate the tests to virtually measure the local loads. The collected fatigue data, from both the real and the virtual test, is utilized in a maximum likelihood method and provides the desired SN curve for the considered cable.

For a first cable type, lifetime experiments with several different installations have been performed and an SN curve could be identified, which fits to the collected fatigue data. Currently, we perform further tests to validate the identified SN curve.

Artikelnummer
VAL5-2024-023

Titel
Simulation-based lifetime prediction for cables
Autor(en)
F. Schneider-Jung, M. Speckert, K. Dreßler
DOI
10.48447/VAL5-2024-023
Veranstaltung
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
Jahr der Veröffentlichung
2024
Publikationsart
Tagungsmanuskript (PDF)
Sprache
Englisch
Stichwörter
Cable Simulation,Lifetime Prediction,SN Curves

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VAL5 Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
VAL5 Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
10.48447/VAL5-2024-BB
978-3-9820591-3-6
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VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
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Publikationsart: Berichtsband (PDF)
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Variable Amplitude Loading, VAL, VAL5 
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Autor(en): L. Solazzi, A. Mazzoni, N. Danzi, M. Cima
10.48447/VAL5-2024-022
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Tagungsmanuskript (PDF)
Englisch
random fatigue,damage counting,wheel,stress acquisition 
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Fatigue analysis of random variable loads acting on wheels for special off-highway applications from experimental data
Fatigue analysis of random variable loads acting on wheels for special off-highway applications from experimental data
L. Solazzi, A. Mazzoni, N. Danzi, M. Cima
10.48447/VAL5-2024-022
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Publikationsart: Tagungsmanuskript (PDF)
Englisch
random fatigue,damage counting,wheel,stress acquisition 
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1
Fatigue analysis of random variable loads acting on wheels for special off-highway applications from experimental data
L. Solazzi, A. Mazzoni, N. Danzi, M. Cima
10.48447/VAL5-2024-022
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Tagungsmanuskript (PDF)
Englisch
random fatigue,damage counting,wheel,stress acquisition
Preis 25,00 €
Nur online erhältlich
Comparative Study of Crack Growth Retardation Models for an Integral Stiffened Panel Subjected to Overload.
Autor(en): J. D. Mattos, M. A. Arbelo
10.48447/VAL5-2024-039
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Tagungsmanuskript (PDF)
Englisch
Overload Retardation Effect,Fatigue Crack-Growth,Integral Stiffened Panel,Aviation Integral Panel 
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Comparative Study of Crack Growth Retardation Models for an Integral Stiffened Panel Subjected to Overload.
Comparative Study of Crack Growth Retardation Models for an Integral Stiffened Panel Subjected to Overload.
J. D. Mattos, M. A. Arbelo
10.48447/VAL5-2024-039
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Publikationsart: Tagungsmanuskript (PDF)
Englisch
Overload Retardation Effect,Fatigue Crack-Growth,Integral Stiffened Panel,Aviation Integral Panel 
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1
Comparative Study of Crack Growth Retardation Models for an Integral Stiffened Panel Subjected to Overload.
J. D. Mattos, M. A. Arbelo
10.48447/VAL5-2024-039
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Tagungsmanuskript (PDF)
Englisch
Overload Retardation Effect,Fatigue Crack-Growth,Integral Stiffened Panel,Aviation Integral Panel
Preis 25,00 €
Nur online erhältlich
Application of the Local Strain Approach to estimate fatigue life of clinched joints under constant and variable amplitude loading in different loading conditions
Autor(en): B. Spak, M. Schlicht, P. Froitzheim, W. Flügge, M. Kästner
10.48447/VAL5-2024-046
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Tagungsmanuskript (PDF)
Englisch
Clinching,mechanical joining,Local Strain Approach,fatigue,variable amplitude loading 
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Application of the Local Strain Approach to estimate fatigue life of clinched joints under constant and variable amplitude loading in different loading conditions
Application of the Local Strain Approach to estimate fatigue life of clinched joints under constant and variable amplitude loading in different loading conditions
B. Spak, M. Schlicht, P. Froitzheim, W. Flügge, M. Kästner
10.48447/VAL5-2024-046
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Publikationsart: Tagungsmanuskript (PDF)
Englisch
Clinching,mechanical joining,Local Strain Approach,fatigue,variable amplitude loading 
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1
Application of the Local Strain Approach to estimate fatigue life of clinched joints under constant and variable amplitude loading in different loading conditions
B. Spak, M. Schlicht, P. Froitzheim, W. Flügge, M. Kästner
10.48447/VAL5-2024-046
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Tagungsmanuskript (PDF)
Englisch
Clinching,mechanical joining,Local Strain Approach,fatigue,variable amplitude loading
Preis 25,00 €
Nur online erhältlich
Computational fatigue assessment for welded copper joints against vibratory loads
Autor(en): M. Lauf, S. Pruy, S. Kiesner, P. Hantschke, M. Kästner
10.48447/VAL5-2024-040
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Tagungsmanuskript (PDF)
Englisch
Vibration Fatigue,Digital Twin,FEM-Simulation,Welded Copper 
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Computational fatigue assessment for welded copper joints against vibratory loads
Computational fatigue assessment for welded copper joints against vibratory loads
M. Lauf, S. Pruy, S. Kiesner, P. Hantschke, M. Kästner
10.48447/VAL5-2024-040
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Publikationsart: Tagungsmanuskript (PDF)
Englisch
Vibration Fatigue,Digital Twin,FEM-Simulation,Welded Copper 
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1
Computational fatigue assessment for welded copper joints against vibratory loads
M. Lauf, S. Pruy, S. Kiesner, P. Hantschke, M. Kästner
10.48447/VAL5-2024-040
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Tagungsmanuskript (PDF)
Englisch
Vibration Fatigue,Digital Twin,FEM-Simulation,Welded Copper
Preis 25,00 €
Nur online erhältlich
A Comparative Analysis: Time vs. Frequency Domain Definitions of the Fatemi-Socie Criterion
Autor(en): A. Niesłony, M. Böhm, M. Sgamma, A. Chiocca, F. Bucchi, F. Frendo
10.48447/VAL5-2024-037
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Tagungsmanuskript (PDF)
Englisch
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A Comparative Analysis: Time vs. Frequency Domain Definitions of the Fatemi-Socie Criterion
A Comparative Analysis: Time vs. Frequency Domain Definitions of the Fatemi-Socie Criterion
A. Niesłony, M. Böhm, M. Sgamma, A. Chiocca, F. Bucchi, F. Frendo
10.48447/VAL5-2024-037
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Publikationsart: Tagungsmanuskript (PDF)
Englisch
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1
A Comparative Analysis: Time vs. Frequency Domain Definitions of the Fatemi-Socie Criterion
A. Niesłony, M. Böhm, M. Sgamma, A. Chiocca, F. Bucchi, F. Frendo
10.48447/VAL5-2024-037
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Tagungsmanuskript (PDF)
Englisch
Fatemi-Socie criterion,frequency domain,vibration fatigue,multiaxial fatigue
Preis 25,00 €
Nur online erhältlich
Non-stationary vibration loading - Assessing its effects on structural dynamics and vibration fatigue
Autor(en): A. Trapp, P. Wolfsteiner
10.48447/VAL5-2024-053
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Tagungsmanuskript (PDF)
Englisch
structural dynamics,non-stationarity matrix,non-stationary vibration loading,random vibration fatigue 
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Non-stationary vibration loading - Assessing its effects on structural dynamics and vibration fatigue
Non-stationary vibration loading - Assessing its effects on structural dynamics and vibration fatigue
A. Trapp, P. Wolfsteiner
10.48447/VAL5-2024-053
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Publikationsart: Tagungsmanuskript (PDF)
Englisch
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1
Non-stationary vibration loading - Assessing its effects on structural dynamics and vibration fatigue
A. Trapp, P. Wolfsteiner
10.48447/VAL5-2024-053
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Tagungsmanuskript (PDF)
Englisch
structural dynamics,non-stationarity matrix,non-stationary vibration loading,random vibration fatigue
Preis 25,00 €
Nur online erhältlich
A demonstrator example for virtual sensing approaches in predictive maintenance applications
Autor(en): L. Heindel, P. Hantschke, M. Kästner
10.48447/VAL5-2024-049
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Tagungsmanuskript (PDF)
Englisch
virtual sensing,predictive maintenance,machine learning 
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A demonstrator example for virtual sensing approaches in predictive maintenance applications
A demonstrator example for virtual sensing approaches in predictive maintenance applications
L. Heindel, P. Hantschke, M. Kästner
10.48447/VAL5-2024-049
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Publikationsart: Tagungsmanuskript (PDF)
Englisch
virtual sensing,predictive maintenance,machine learning 
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1
A demonstrator example for virtual sensing approaches in predictive maintenance applications
L. Heindel, P. Hantschke, M. Kästner
10.48447/VAL5-2024-049
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Tagungsmanuskript (PDF)
Englisch
virtual sensing,predictive maintenance,machine learning
Preis 25,00 €
Nur online erhältlich
Experimental research on fatigue self-awareness of single-process 3d-printed structures
Autor(en): M. Palmieri, A. Staffa, J. Slavic, F. Cianetti
10.48447/VAL5-2024-050
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Tagungsmanuskript (PDF)
Englisch
Additive manufacturing,Vibration fatigue,Smart structures,3D-printed strain sensors 
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1
Experimental research on fatigue self-awareness of single-process 3d-printed structures
Experimental research on fatigue self-awareness of single-process 3d-printed structures
M. Palmieri, A. Staffa, J. Slavic, F. Cianetti
10.48447/VAL5-2024-050
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Publikationsart: Tagungsmanuskript (PDF)
Englisch
Additive manufacturing,Vibration fatigue,Smart structures,3D-printed strain sensors 
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1
Experimental research on fatigue self-awareness of single-process 3d-printed structures
M. Palmieri, A. Staffa, J. Slavic, F. Cianetti
10.48447/VAL5-2024-050
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Tagungsmanuskript (PDF)
Englisch
Additive manufacturing,Vibration fatigue,Smart structures,3D-printed strain sensors
Preis 25,00 €
Nur online erhältlich
Dynamic fatigue analysis of a welded joints under sequential and simultaneous multi-axial random PSD loading
Autor(en): A. Halfpenny, S. Vervoort
10.48447/VAL5-2024-027
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Tagungsmanuskript (PDF)
Englisch
Fatigue,vibration,multiaxial,spot weld,battery pack 
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1
Dynamic fatigue analysis of a welded joints under sequential and simultaneous multi-axial random PSD loading
Dynamic fatigue analysis of a welded joints under sequential and simultaneous multi-axial random PSD loading
A. Halfpenny, S. Vervoort
10.48447/VAL5-2024-027
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Publikationsart: Tagungsmanuskript (PDF)
Englisch
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1
Dynamic fatigue analysis of a welded joints under sequential and simultaneous multi-axial random PSD loading
A. Halfpenny, S. Vervoort
10.48447/VAL5-2024-027
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Tagungsmanuskript (PDF)
Englisch
Fatigue,vibration,multiaxial,spot weld,battery pack
Preis 25,00 €
Nur online erhältlich
Influence of variable amplitude loading on copper-alloyed components
Autor(en): M. Hupka, M. Wächter, A. Esderts
10.48447/VAL5-2024-042
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Tagungsmanuskript (PDF)
Englisch
Copper Alloys,Analytical Fatigue Assessment,Component-related Influences 
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1
Influence of variable amplitude loading on copper-alloyed components
Influence of variable amplitude loading on copper-alloyed components
M. Hupka, M. Wächter, A. Esderts
10.48447/VAL5-2024-042
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Publikationsart: Tagungsmanuskript (PDF)
Englisch
Copper Alloys,Analytical Fatigue Assessment,Component-related Influences 
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1
Influence of variable amplitude loading on copper-alloyed components
M. Hupka, M. Wächter, A. Esderts
10.48447/VAL5-2024-042
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Tagungsmanuskript (PDF)
Englisch
Copper Alloys,Analytical Fatigue Assessment,Component-related Influences
Preis 25,00 €
Nur online erhältlich
Fatigue behaviour of specimen and rotor lamellas of non-grain oriented electrical steel under constant and variable amplitude loading
Autor(en): P. Schwarz, P. Häfele, T. Langlois
10.48447/VAL5-2024-026
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Tagungsmanuskript (PDF)
Englisch
electrical steel strip,Variable amplitude fatigue,cut-edge,notch influence,real damage sum 
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Fatigue behaviour of specimen and rotor lamellas of non-grain oriented electrical steel under constant and variable amplitude loading
Fatigue behaviour of specimen and rotor lamellas of non-grain oriented electrical steel under constant and variable amplitude loading
P. Schwarz, P. Häfele, T. Langlois
10.48447/VAL5-2024-026
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Publikationsart: Tagungsmanuskript (PDF)
Englisch
electrical steel strip,Variable amplitude fatigue,cut-edge,notch influence,real damage sum 
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1
Fatigue behaviour of specimen and rotor lamellas of non-grain oriented electrical steel under constant and variable amplitude loading
P. Schwarz, P. Häfele, T. Langlois
10.48447/VAL5-2024-026
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Tagungsmanuskript (PDF)
Englisch
electrical steel strip,Variable amplitude fatigue,cut-edge,notch influence,real damage sum
Preis 25,00 €
Nur online erhältlich
A critical plane criterion for non-stationary random vibration loading applicable in a statistical fatigue assessment
Autor(en): A. Trapp, K. Schneider, K. Rother, P. Wolfsteiner
10.48447/VAL5-2024-048
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Tagungsmanuskript (PDF)
Englisch
critical plane criterion,non-stationary loading,non-stationarity matrix,multiaxial fatigue,random vibration fatigue 
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A critical plane criterion for non-stationary random vibration loading applicable in a statistical fatigue assessment
A critical plane criterion for non-stationary random vibration loading applicable in a statistical fatigue assessment
A. Trapp, K. Schneider, K. Rother, P. Wolfsteiner
10.48447/VAL5-2024-048
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Publikationsart: Tagungsmanuskript (PDF)
Englisch
critical plane criterion,non-stationary loading,non-stationarity matrix,multiaxial fatigue,random vibration fatigue 
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1
A critical plane criterion for non-stationary random vibration loading applicable in a statistical fatigue assessment
A. Trapp, K. Schneider, K. Rother, P. Wolfsteiner
10.48447/VAL5-2024-048
VAL5 - Fifth International Conference on Material and Component Performance under Variable Amplitude Loading
2024
Tagungsmanuskript (PDF)
Englisch
critical plane criterion,non-stationary loading,non-stationarity matrix,multiaxial fatigue,random vibration fatigue
Preis 25,00 €
Nur online erhältlich