Delivery Van Stress & Life Analysis

Belcan supported design of a next generation delivery van by performing test support, data reduction, and structural analysis of an existing design and recommending design improvements based on the results.

Belcan engineers positioned strain gauges and accelerometers and monitored vehicle durability testing. Upon completion of testing, Belcan reduced test data to identify the significant fatigue lifing events and generated Power Spectral Density (PSD) tables for dynamic simulation.

Concurrent to the testing, a finite element model of the current design was generated using shell and solid elements. The major structural components of the vehicle were explicitly modeled including the truck body and chassis. Beam, spring, and mass elements were used to simulate all other vehicle components contributing to dynamic performance including engine, suspension system, and tires.

Modal and PSD analysis was performed on the full van model to obtain total dynamic loads throughout the vehicle structural components. Local submodels were generated at high stress locations and run to determine accurate stresses for fatigue estimation.

Fatigue life was calculated for submodeled components using Neuber’s rule and Coffin Manson equations and accumulating damage from the significant events. Design changes were recommended to greatly enhance fatigue life throughout the vehicle.

Belcan expertise provided the analysis methodology and execution our client needed to design a new generation delivery van that could compete in today’s market.