Durability Assessment of a Connecting Rod

The Challenge

An automotive manufacturer needed to test the durability of a component to ensure it met the operating requirements and provided the product life required, but physical testing is time consuming and costly.

The Solution

BEASY 3D crack growth simulation was used to perform virtual testing to predict how cracks would grow if they were present in the component. The cracks could be present through material or manufacturing defects or initiated by the fatigue loads in service. Virtual fracture testing was performed on the part by simulating how cracks would grow if found at various locations on the connecting rod. The BEASY crack modelling technology provided an easy way to quickly add cracks of various sizes and locations into a 3D model of the actual connecting rod to predict the crack growth rates, critical crack sizes and failure modes.

The Value

The simulations and the data provided was used to optimise the testing programme and reduce the number of actual tests performed. This reduced the time and costs for testing and provided a clearer understanding of how and why the component would fail and how the design could be changed to improve durability.

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