Abstract:In this research, stress measurement tests and advanced application algorithms based on computer-aided design and engineering (CAD and CAE) were developed and tested. The algorithm was put implemented through a case study on the strength-based structural design and fatigue analysis of a chassis. This algorithm consists of numerical and experimental methods and additionally includes material tests, three-dimensional CAD, a finite element method (FEM)-based analysis procedures, a structural optimization strategy… Show more
“…In the finite element analysis solution performed for the application part for a load of 50 kN, the strain at the strain gauge position was obtained as 22.624 MPa (Fig. 13) [2]. This numerical result is very close to the measured stress value.…”
Section: Resultssupporting
confidence: 70%
“…The data acquisition system is selected depending on how many gauges will be collected simultaneously. Special software is also used to display and save strain data from the data acquisition system [2]. Connections of the strain gauges and measurement calculations are also a specialty.…”
This study investigated electrical strain gage technology, which is widely used in experimental stress measurement, on an application. Strain gages are used to precisely measure strain directly in a system. This method is carried out to verify the numerical and analytical calculations performed or to record the strain data generated during the active duty of a system and to investigate the fatigue damage. In particular, verifying numerical calculations in the strength-material recovery optimizations of mass-produced systems contributes to the development of the system. In this study, strain measurement using strain gage and strain measurement technology is presented on an application. Information was given about strain gages. A full bridge wheatstone bridge consisting of 4 linear gages was created on a prototype. The system was tested with a load cell validation. Structural finite element analysis of the prototype and analytical calculation of the fullbridge strain gage connection were performed. The results showed that the measurement with the strain gauge differed 1.20% and 1.40% from the analytical and numerical results, respectively. Thus, precision strain measurement technology was successfully presented in engineering systems.
“…In the finite element analysis solution performed for the application part for a load of 50 kN, the strain at the strain gauge position was obtained as 22.624 MPa (Fig. 13) [2]. This numerical result is very close to the measured stress value.…”
Section: Resultssupporting
confidence: 70%
“…The data acquisition system is selected depending on how many gauges will be collected simultaneously. Special software is also used to display and save strain data from the data acquisition system [2]. Connections of the strain gauges and measurement calculations are also a specialty.…”
This study investigated electrical strain gage technology, which is widely used in experimental stress measurement, on an application. Strain gages are used to precisely measure strain directly in a system. This method is carried out to verify the numerical and analytical calculations performed or to record the strain data generated during the active duty of a system and to investigate the fatigue damage. In particular, verifying numerical calculations in the strength-material recovery optimizations of mass-produced systems contributes to the development of the system. In this study, strain measurement using strain gage and strain measurement technology is presented on an application. Information was given about strain gages. A full bridge wheatstone bridge consisting of 4 linear gages was created on a prototype. The system was tested with a load cell validation. Structural finite element analysis of the prototype and analytical calculation of the fullbridge strain gage connection were performed. The results showed that the measurement with the strain gauge differed 1.20% and 1.40% from the analytical and numerical results, respectively. Thus, precision strain measurement technology was successfully presented in engineering systems.
“…This confirms that ANSYS results are particularly successful in 2D solution. Çelik et al 66 found a closeness of ∼11.7% in their study, and İrsel 36 found a closeness of about ∼5%. For this reason, researchers determined that the ANSYS results obtained are compatible with both experiments and studies in the literature. Figure 22. Three-point and four-point bending FEM results for 100 kN load (a) Three-point bending test of X-section beam (b) Four-point bending test of X-section beam (c) Three-point bending test of square section beam and (d) Four-point bending test of square section beam. Figure 23. Plasticity solutions of beams and experimental results (a) X-section beam three-point FEM solution (b) X-section beam three-point test (c) X-section four-point FEM solution (d) X-section four-point test (e) 120 × 120 × 8 mm square beam three-point FEM solution (f) 120 × 120 × 8 mm square beam three-point test (g) 120 × 120 × 8 mm square beam four-point FEM solution (h) 120 × 120 × 8 mm square beam three-point test.…”
Section: Resultsmentioning
confidence: 66%
“…The skewness value, which shows the mesh quality in the FE model is 0.174. This skewness value is appropriate according to the range of skewness values table and corresponding cell quality 36,52,53 (Figure 15). On the workstation mentioned above, the solutions took an average of 34.9 s, and 8 Gb of Ram was used for the solution.…”
Section: Cad Modeling and Fem Solutionmentioning
confidence: 99%
“…It detects critical locations for fatigue damage in the system and the fatigue damage risk distribution throughout the system and calculates realistic fatigue lifetimes. [34][35][36] The most effective way of fatigue evaluation is postprocessing of FEA results of structural analysis in the form of stress/strain fields (geometry input) in combination with the input of load history and fatigue material data. 34 Gawande et al 37 determined a relevance between experimental test results and nCode DesignLife results.…”
Thin-walled hollow shapes are of great interest in many industries with weight constraints, due to their availability, low price, and strength-to-weight ratio. This paper presents the development, calculation, and production of a thin-walled X-section beam design with a unique section geometry. This hollow X-section beam geometry is a beam that has been developed to use shape-connected jaws on the beam and to use less bolts and mounting elements, and to easily change the positions of the parts mounted on the beam. The bending strength of this unique beam section was investigated, and the fatigue damage of the beam was also handled with technological methods. Using both experimental stress measurements and finite element solution, the static and fatigue strength of the beam were calculated with computer-aided engineering software. The FEM solution was performed nonlinearly by defining the linear elastic and plasticity properties of the material. Validation studies were carried out in the laboratory using three-point and four-point bending tests. These traditional experiments were supported by strain gauge technology that measures strain with 0.05% accuracy. The weight and bending strength of the X-section beam were compared with the hollow section square beam. X-section beam (S355J0H) has 13% lower bending strength than 120 × 120 × 8 mm (S355J0H) beam; however, it is 37% lighter. ANSYS-analytical test results of difference are 3.95%, and ANSYS-experimental test results of difference are 0.85%. Experiments showed that a ∼22% increase in strength is found in these corners depending on the production method. The fatigue behavior of the X-section beam was determined with the nCode DesignLife software using validated FEM solutions and fatigue curves of the materials. X-section beam developed for shape–connected assembly systems can be used especially in the formation of chassis with its superior assembly ability and bending strength, increasing functionality, and production speed.
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