Road Simulation Bench as a Tool to Reduce Time and Costs in Comparison with Proving Ground Testing - Correlation Study

摘要

Fatigue tests on exhaust system usually require long time to be performed on the proving ground. Road simulation bench test reduces the time needed to execute the entire fatigue test on the proving ground and does not involve the operator presence for long time as proving ground test requires. In order to put on evidence the potentiality of performing the fatigue test with the RSB in substitution of the fatigue test on proving ground, a correlation between virtual analysis, the proving ground test and RSB test are illustrated. A specific component of the exhaust system is studied and specifically the bracket connecting the flexible pipe to the vehicle under body. During the proving ground test several failures occurred on the bracket connecting the exhaust system and the gear box. A virtual FE calculation and a fatigue test on the Road Simulation Bench were required to investigate the failure. The results of both the analyses showed a critical condition for the bracket. During the Road Simulation Bench fatigue test the failure of the bracket is registered shortly before the one on proving ground; this shows that bench conditions for the component are conservatives compared with real ones. The bench does not underestimate the real condition of road test.