Riassunto analitico
Vibration-induced fatigue failure is a critical issue in various engineering applications, ranging from aerospace to automotive and civil structures. This paper presents an investigation into the root causes and mechanisms of a recent vibration fatigue failure observed in a F1 car structural component.
The objective of this study is to gain a comprehensive understanding of the failure mechanism, to identify the key factors contributing to fatigue damage, and to define a FEM methodology capable of replicating and predicting such kind of phenomena.
The investigation begins with a detailed analysis of the failed component, including visual examination and documentation of fracture surfaces. In order to understand the environmental factors determining the fatigue failure, the operating conditions of the component were thoroughly assessed. This involved analyzing the vibration spectra, acceleration levels, and frequency content during the service life. Finite element analysis was conducted to virtually replicate the operating conditions and provide a deeper insight into the stress distribution caused by vibration. To improve the accuracy of the results, the dynamic behavior of the FE model was correlated with that of its physical counterpart by means of an experimental modal analysis.
Based on the comprehensive investigation, several factors were identified as contributors to the vibration fatigue failure. These include high cyclic stress induced by resonance conditions and local stress concentrations at critical locations. Different versions of the component were analyzed and compared, with the aim of relating their constructive differences to their different durability. Finally, the FEM methodology was validated by comparison with the results of a fatigue shaker test.
This investigation provides valuable insights into the complex nature of vibration-induced fatigue failures and highlights the importance of a multidisciplinary approach for failure analysis. The findings of this study can serve as a basis for the integration of the vibration fatigue analysis in the design validation phase of mechanical components.
|
