Contents. Preface... xv Acknowledgments... xix About the Authors... xxi Nomenclature... xxiii

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2 Preface... xv Acknowledgments... xix About the Authors... xxi Nomenclature... xxiii Chapter 1: Road Load Analysis Techniques in Automotive Engineering... 1 Xiaobo Yang, Peijun Xu Introduction... 1 Fundamentals of Multibody Dynamics... 4 Conditions of Equilibrium... 6 D Alembert s Principle... 7 Multibody Dynamics Systems Generic Load Cases Generic Load Events Analysis Procedure Results and Report Semianalytical Analysis Powertrain Mount Load Analyses Suspension Component Load Analysis Vehicle Load Analysis Using 3D Digitized Road Profiles Vehicle Model Description Tire Model Description Model Validation Process Summary References vii

3 Chapter 2: Pseudo Stress Analysis Techniques Yung-Li Lee, Mingchao Guo Introduction Static Stress Analysis Fixed Reactive Analysis Inertia Relief Analysis Modal Transient Response Analysis Natural Frequencies and Normal Modes Orthonormalization of Normal Modes Decoupled Modal Equations of Motion Numerical Integration Method for Equations of Motion Summary References Chapter 3: Rainflow Cycle Counting Techniques Yung-Li Lee, Tana Tjhung Introduction Uniaxial Rainflow Cycle Counting Techniques Rainflow Counting Method by Matsuishi and Endo Three-Point Counting Technique Four-Point Counting Technique Multiaxial Rainflow Reversal Counting Techniques Summary References Chapter 4: Stress-Based Uniaxial Fatigue Analysis Yung-Li Lee, Mark E. Barkey Introduction Ultimate Tensile Strength of a Component Reliability Correction Factor Size Correction Factor Temperature Correction Factor for Ultimate and Yield Strengths Stress Correction Factor Load Correction Factor Component Endurance Limit under Fully Reversed Loading Temperature Correction Factor Endurance Limit Factor viii

4 Surface Treatment Factor Roughness Correction Factor Fatigue Notch Factor Constant Amplitude Stress-Life Curve for a Notched Component under Fully Reversed Loading Constant Amplitude Nominal Stress-Life Curve Constant Amplitude Pseudo Stress-Life Curve Stress-Life Curve for a Component under Variable Amplitude Loading Mean Stress Effect Summary References Chapter 5: Stress-Based Multiaxial Fatigue Analysis Yung-Li Lee, Mark E. Barkey Introduction Fatigue Damage Models Empirical Formula Approach Equivalent Stress Approach Critical Plane Approach Dang Van s Multiscale Approach Summary References Chapter 6: Strain-Based Uniaxial Fatigue Analysis Yung-Li Lee, Mark E. Barkey Introduction Steady State Cyclic Stress Strain Relation Fully Reversed, Constant Amplitude Strain-Life Relation Estimate of Cyclic Material and Fatigue Properties Strain-Life Equations with Mean Stress Morrow Smith, Watson, and Topper Notch Analysis Neuber Nominally Elastic Behavior Nominally Gross Yielding of a Net Section Modified Neuber Rule ix

5 Molsky and Glinka Applications Summary References Chapter 7: Fundamentals of Cyclic Plasticity Theories Yung-Li Lee, Mark E. Barkey Introduction Tensor Notations Theory of Elasticity Monotonic Plasticity Theories Yield Surface Function Isotropic Hardening Flow Rules Plastic Strains Cyclic Plasticity Theories Elastic and Plastic Processes Associated Flow Rule Consistency Condition Kinematic Hardening Models Determination of a Generalized Plastic Modulus Stresses and Strains Applications: Notch Analyses Based on Pseudo Stresses Hoffmann and Seeger Buczynski and Glinka Lee, Chiang, and Wong Summary References Chapter 8: Strain-Based Multiaxial Fatigue Analysis Mark E. Barkey, Yung-Li Lee Introduction Fatigue Damage Models Equivalent Strain Approaches Energy Approaches Critical Plane Approaches Strain Gage Rosette Analysis Strain Data Acquisitions Fatigue Analysis with Plasticity x

6 Summary References Chapter 9: Vibration Fatigue Testing and Analysis Yung-Li Lee, Hong-Tae Kang Introduction Swept Sinusodial or Single-Frequency Sweep Test Response to a Linear Single-Degree-of-Freedom System Subjected to Sinusoidal-Based Excitation Fatigue Damage Calculation Random Vibration Test Characteristics of Random Vibration Responses to a Linear Single-Degree-of-Freedom System Subjected to Base Random Vibration Fatigue Damage Models under Random Stress Process Summary References Chapter 10: Fatigue Life Prediction Methods of Seam-Welded Joints Hong-Tae Kang, Yung-Li Lee Introduction Parameters Affecting Fatigue Lives of Seam-Welded Joints Fatigue Life Prediction Methods Nominal Stress Approaches Structural Stress Approaches Notch Pseudo Stress or RXMS Approach Summary References Chapter 11: Fatigue Life Prediction Methods of Resistance Spot-Welded Joints Hong-Tae Kang, Yung-Li Lee Introduction Parameters Affecting Spot-Welded Joints Nugget Diameter Sheet Metal Thickness xi

7 Specimen Width Base Metal Strength Specimen Type Multiaxial Loading Fatigue Life Prediction Methods Load Life Approach Linear Elastic Fracture Mechanics Approach Structural Stress Approach Applications Summary References Chapter 12: Design and Analysis of Metric Bolted Joints VDI Guideline and Finite Element Analysis Yung-Li Lee, Hsin-Chung Ho Introduction Overview of Bolted Joints and Mechanical Properties Estimate of a Bolt Diameter Estimate of Joint Elastic Compliance (Resilience) Elastic Compliance of a Bolt Elastic Compliance of Clamped Plates for Concentrically Bolted Joints External Loads Load Plan Factor (n) and Load Factor (Φ) Assembly Loads on Bolted Joints Embedding Effect Tightening Torque Assembly Preload Clamped Plate Pressure Minimum Thread Engagement Length Service Loads on Bolted Joints Bolt Yielding Due to Overstressing Clamp Load Loss Due to Gapping Thread Stripping Clamped Plates Crushing Due to Excessive Pressure Slipping Due to Transverse Loads Fatigue Failure Application Solution xii

8 Finite Element-Based Fatigue Analysis of Thread Bolts Solid Bolt Model Spider Bolt Model Summary References Index xiii

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