FORSCHUNGSGESELLSCHAFT
KRAFTFAHRWESEN mbH
Durability Analysis
ika/fka are equipped with an extensive servo-hydraulic
test centre for research and development projects within
the field of durability analysis.
As the test facilities are highly flexible, the entire spec-
trum of possible applications can be considered ranging
from the examination of single components and extensive
multi-axial component tests up to heavy industrial vehicle
testing.
The technical data of the servo hydraulic test facility is
given below:
• 9 linear hydraulic cylinders
• maximum test force: 250 kN
• maximum test frequency: 200 Hz
• maximum capacity per cylinder: 400 mm
• 2 tensioning fields
- 6 m x 15 m with 550 t total weight
- 3 m x 15 m with 16 t total weight
• durability analysis for complete vehicles up to a length
of 13.5 m and up to 35 t total eight
www.fka.de www.ika.rwth-aachen.de
AACHEN
ANGEWANDTE FORSCHUNG, ENTWICKLUNG UND CONSULT
• climatic chamber for component tests in the tempera-
ture range of -40 °C up to +250 °C
• modular test bench system for time- and cost efficient
test configurations
• ITFC or RPC- control
The applied servo-hydraulic testing technology, in con-
trast to corresponding driving tests, provides several
advantages for the durability analysis on complex vehicle
structures and subsystems.
Next to an improved comparability and reproducibility, the
possibility results for example, to reduce the testing time
significantly by time-lapsing test programs.
A ride on a straight track will be simulated by a vertical
excitation with up to nine cylinders for the experimental
investigation of the durability of vehicle bodies on basis of
vertical damage proportions. The test vehicle is subjected
to a test program during this testing, which is specially
developed for time-lapsing durability test at body struc-
tures.
Generally 80 % of the total damage will be determined by
this simplified test.
Measured load profiles can be represented true to origi-
nal in real time on the test bench by means of the avail-
able test bench software (ITFC or RPC). Thus the possi-
bility is provided, to check modifications at the vehicle
fast and easily in the test laboratory.
gb2-03e_durability_analysis.doc, 22.06.04
Calculative Durability Analysis
Next to experimental durability analysis, we also realise
numerical durability simulations. Thus following programs
are used predominantly:
• FALANCS
• FemFat and
• MSC/Fatigue.
The durability simulation provides the opportunity to
simulate and also to evaluate the component behaviour
under cyclic loading.
On basis of generated or measured load collectives,
The application of the durability simulation leads, next to
load-time at the component are firstly determined with the
cost savings also to significantly shortened development
help of multi-body simulations (MKS). So-called stan-
times in the frame of the development process.
dardized load cases are calculated for the acting, time-
variable forces and moments at the component by the
use of the Finite Element Method.

The calculated tension- and expansion data will be read

in the durability program together with the cyclic material
parameters.
Among other things, also weaknesses are identified at
the durability simulation, which prove itself as uncritical
during the static analysis.
By this means first statements about the service life of
different construction variants of components or assem-
bly groups can be made very quick in an early develop-
ment stage. Thus the number of prototypes in the devel-
opment process can be reduced.

www.fka.de www.ika.rwth-aachen.de gb2-03e_durability_analysis.doc, 22.06.04