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Abstract
Rubber components, which have been widely used in the automotive industry as anti-
vibration components for many years, are subjected to uctuating loads, often failing due
to the nucleation and growth of defects or cracks. To prevent such failures, it is necessary
to understand the fatigue failure mechanism for rubber materials and to evaluate the
fatigue life for rubber components. The objective of this study is to develop a durability
analysis process for vulcanized rubber components, that can predict fatigue life at the
initial product design step. The determination method of nonlinear material constants for
FE analysis was proposed. Also, to investigate the applicability of the commonly used
damage parameters, fatigue tests and corresponding nite element analyses were carried
out and normal and shear strain was proposed as the fatigue damage parameter for
rubber components. Fatigue analysis for automotive rubber components was performed
and the durability analysis process was reviewed. KeywordsFatigue lifeFatigue damage
parameterRubber componentSuspension bush
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(Manuscript Received May 31, 2010; Revised August 5, 2010; Accepted January 6, 2011)
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Abstract
Rubber components, which have been widely used in the automotive industry as anti-vibration components for many years, are sub-
jected to fluctuating loads, often failing due to the nucleation and growth of defects or cracks. To prevent such failures, it is necessary to
understand the fatigue failure mechanism for rubber materials and to evaluate the fatigue life for rubber components. The objective of
this study is to develop a durability analysis process for vulcanized rubber components, that can predict fatigue life at the initial product
design step. The determination method of nonlinear material constants for FE analysis was proposed. Also, to investigate the applicability
of the commonly used damage parameters, fatigue tests and corresponding finite element analyses were carried out and normal and shear
strain was proposed as the fatigue damage parameter for rubber components. Fatigue analysis for automotive rubber components was
performed and the durability analysis process was reviewed.
Keywords: Fatigue life; Fatigue damage parameter; Rubber component; Suspension bush
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1160 S.-I. Moon et al. / Journal of Mechanical Science and Technology 25 (5) (2011) 1159~1165
Fig. 2. Nonlinear material constant tests: (a) simple tension; (b) equi- (a)
biaxial; (c) pure shear.
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S.-I. Moon et al. / Journal of Mechanical Science and Technology 25 (5) (2011) 1159~1165 1161
ial tension and pure shear test, were carried out and the strain
levels were progressively increased up to the maximum value,
1.0. Fig. 3 shows the stress-strain curves for each stress state
and equibiaxial tension, pure shear and simple tension arrange
in order of stiffness magnitude. The non-linear material con-
Z
stants were determined through curve fitting for these stress-
Y X strain curves and presented in Table 2.
(a) (b) 2.3 Fatigue material property
Fig. 4. Fatigue specimen: (a) dumbbell specimen; (b) FE model. The three-dimensional (3D) dumbbell specimens shown in
Fig. 4(a) were used for fatigue tests. To determine a fatigue
damage parameter of the rubber material and fatigue life, fa-
tigue tests using 3D dumbbell specimens were conducted in
Mean Displacement, mm
[11] package was used for the finite element analysis. Fig.
4(b) shows a finite element mesh of the 3D dumbbell speci-
men. An eighth of the specimen was modeled by considering
the symmetry condition and the mesh was constructed with 8-
node linear brick, hybrid elements. The number of nodes and
elements of the model is 20,157 and 4,340, respectively. The
nodes on the lower surface of the model were constrained, and
those on the upper surface were controlled with displacement
(a) according to the loading condition. It was assumed that fatigue
life was determined by the maximum value of fatigue damage
parameters [3]. From a series of finite element analysis results
and test results, the relationship between the fatigue life and
the typical fatigue damage parameters, principal stain and
Log(Strain)
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1162 S.-I. Moon et al. / Journal of Mechanical Science and Technology 25 (5) (2011) 1159~1165
Table 3. Loading condition for fatigue test. Table 4. Basic material properties searched from RubPRO.
(a) (b)
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S.-I. Moon et al. / Journal of Mechanical Science and Technology 25 (5) (2011) 1159~1165 1163
Z
Y X
(a) (b)
Fig. 9. Finite element mesh of suspension bush.
Fig. 11. Contour plots of SED and principal strain: (a) SED; (b) 1st
principal strain.
1 1
2 2
0.72 0 .56
0. 81 0. 64 0 .43 0. 68
(a) (a) (b)
Fig. 12. Mohrs circle for strain at (a) MAX. SED point; (b) MAX.
strain point.
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1164 S.-I. Moon et al. / Journal of Mechanical Science and Technology 25 (5) (2011) 1159~1165
dominantly influences the failure of rubber components. (4) To estimate more accurate fatigue life, not only normal
strain but also shear strain should be considered, and fatigue
3.4 Fatigue life prediction for rubber component properties for shear deformation are needed.
The fatigue life was calculated by using SED and first prin-
cipal strain obtained from finite element analyses. The fatigue
References
properties measured by using 3D dumbbell specimens were
used, and the relationship between fatigue life and fatigue [1] Korea Institute of Machinery and Materials, Development of
damage parameters, SED and first principal strain, was pre- Integrated Design System for Mechanical Rubber Compo-
sented as follows: nents, M1-9911-00-0014 (2004).
2.063
[2] A. N. Gent, Engineering with Rubber, Hanser Gardner
N f = 190,546 ( SED ) (2) (2001).
N f = 21,314 ( Strain )
4.521
(3) [3] C. S. Woo, W. D. Kim and J. D. Kwon, A Study on the Fa-
tigue Life Prediction and Evaluation of Rubber Components
where Nf is fatigue life. for Automobile Vehicle, Transaction of KSME, 13 (6)
The fatigue life calculated by using SED and first principal (2005) 56-62.
strain was underestimated, and the fatigue life normalized [4] C. H. Kim, K. J. Kim, H. T. Jeong, C. W. Kim, I. S. Sohn
with fatigue test results was 0.33 and 0.52, respectively. As and J. B. Kim, Prediction of Durability, Static and Dynamic
stated above, it is thought that these underestimated results are Properties on Rubber, Transaction of KSME, 14 (6) (2006)
caused by shear deformation. SED is a scalar quantity, so it 17-23.
does not predict crack nucleation in a specific orientation. [5] C. S. Woo, W. D. Kim and J. D. Kwon A Study on the Ma-
Also, equibiaxial tension fatigue life was longer than simple terial Properties and Fatigue Life Prediction of Natural Rub-
tension fatigue life by a factor of approximately 4, when com- ber Component, Material Science and Engineering (2008)
pared based on equal strain energy density [8]. Therefore, it is 367-381.
not appropriate to evaluate the fatigue life of rubber compo- [6] J. H. Kim and H. Y. Jeong, A Study on the Material Proper-
nents by using SED. Also, if normal deformation is dominant ties and Fatigue Life of Natural Rubber with Different Car-
in failure mode, the fatigue life can be estimated by using bon Blacks, Internal Journal of Fatigue, 27 (2005) 263-272.
maximum principal strain as fatigue damage parameter [3, 5]. [7] B. J. Roberts and J. B. Benzies, The Relationship between
Thus, for the purpose of more accurate fatigue life, both nor- Uniaxial and Equibiaxial Fatigue in Gum and Carbon black
mal strain and shear strain should be considered. Moreover, filled Vulcanizates, Proceedings of Rubbercon, 2.1 (1997)
fatigue properties for shear deformation are needed as well. 2.1-2.13.
[8] W. V. Mars and A. Fatemi, A Literature Survey on Fatigue
Analysis Approaches for Rubber, International Journal of
4. Conclusions
Fatigue, 24 (2002) 949-961.
To develop a durability analysis process for vulcanized rub- [9] GM, Standard Test Methods for Vulcanized Rubber and
ber components, that is applicable to predicting fatigue life at TPE for Use in finite Element Analysis Modeling .
initial product design stage, a methodology is proposed to [10] N. Andre, G. Cailletaud and R. Piques, Haigh Diagram for
extract the material properties for FEA from basic test results. Fatigue Crack Initiation Prediction of Natural Rubber Com-
Also, to investigate the applicability of commonly used fa- ponents, Kautschuk Und Gummi dunstoffe, 52 (1999) 120-
tigue damage parameters, fatigue tests and corresponding 123.
finite element analyses were carried out and optimum fatigue [11] Dassault Systems, ABAQUS Version 6.8 Users manual
damage parameter was selected. The key findings and results (2008).
are as follows:
(1) A methodology to extract the non-linear material prop-
erties for FEA from the rubber material database of Korea Seong In Moon received his B.S., M.S.
Institute of Machinery and Materials, RubPRO, and basic test and Ph. D. in Mechanical Design from
results was proposed. Sungkyunkwan University in 1999,
(2) Strain energy density as a fatigue damage parameter ac- 2001 and 2005 in Korea. He worked for
curately predicted the crack initiation point, but the predicted Hyundai Motors as a senior researcher
fatigue life showed a big discrepancy of 77% with test results. from 2005 to 2009. He is currently a
(3) First principal strain as a fatigue damage parameter did senior researcher in Korea Atomic
not predict the crack initiation point and the fatigue life. The Energy Research Institute. His research
predicted fatigue life showed a big discrepancy of 52% with interests are durability evaluation of mechanical system and
test results. nuclear fuel cycle facility design.
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S.-I. Moon et al. / Journal of Mechanical Science and Technology 25 (5) (2011) 1159~1165 1165
Il Je Cho received his B.S. and M.S. in Wan Doo Kim received his B.S, M.S
Nuclear Engineering from Hanyang and Ph.D. in Mechanical Engineering
University in 1996 and 1998 in Korea. from Seoul National University in 1980,
He is currently a senior researcher in 1982 and 1993. He is currently a ten-
Korea Atomic Energy Research Insti- ured researcher at Korea Institute of
tute. His research interests are nuclear Machinery and Materials, and a steering
fuel cycle facility design (hot-cell), committee member of National Science
management of spent fuel, and safety and Technology Council. His research
issues of nuclear fuel cycle. interests are nature-inspired technology, rubber mechanics and
sustainable mechanical design.
Chang Su Woo received his M.S from
Seoul National University in 1987 and
Ph.D. in Mechanical Engineering in
2003 from Youngnam University. He
was recruited in 1989 by the Korea
Institute of Machinery and Materials
(KIMM) to work on fatigue analysis of
mechanical components. He has pub-
lished approximately 50 papers relating to research on rubber
engineering components, and their applications, such as auto-
motive mounts and bushings, suspension of railway vehicles,
shock & vibration isolators, and structure energy dissipation
systems.
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Citations 7 References 8
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