Abstract
The experimental investigation of viscoelastic behavior of cyclically loaded elastomeric components with respect to the time and the frequency domain is critical for industrial applications. Moreover, the validation of this behavior through numerical simulations as part of the concept of virtual prototypes is equally important. Experiments, combined measurements and test setups for samples as well as for rubber-metal components are presented and evaluated with regard to their industrial application. For application in electric vehicles with relevant excitation frequencies substantially higher than by conventional drive trains, high-frequency dynamic stiffness measurements are performed up to 3000 Hz on a newly developed test bench for elastomeric samples and components. The new test bench is compared with the standard dynamic measurement method for characterization of soft polymers. A significant difference between the measured dynamic stiffness values, caused by internal resonance of the bushing, is presented. This effect has a direct impact on the acoustic behavior of the vehicle and goes undetected by conventional measurement methods due to their lower frequency range. Furthermore, for application in vehicles with internal combustion engine, where the mechanical excitation amplitudes are significantly larger than by vehicles with electric engines, a new concept for the identification of viscoelastic material parameters that is suitable for the representation of large periodic deformations under consideration of energy dissipation is described. This dissipated energy causes self-heating of the polymer and leads to the precocious aging and failure of the elastomeric component. The validation of this concept is carried out thermally and mechanically on specimen and component level. Using the approaches developed in this work, the behavior of cyclically loaded elastomeric engine mounts in different applications can be simulated to reduce the time spent and save on the costs necessary for the production of prototypes.
Highlights
The development of technically advanced vehicles or machines requires consideration of their surrounding components and of several different effects
It is important to assure that the loaded sample is still in the so-called linear viscoelastic region (LVR), which is the main assumption that is made in Dynamic Mechanical Thermal Analysis (DMTA) measurements
For applications in electric vehicles, the vibrations caused by Permanent magnet synchronous motors (PMSM) are of small amplitude with wide frequency range
Summary
The development of technically advanced vehicles or machines requires consideration of their surrounding components and of several different effects. The material behavior of elastomeric samples or components loaded by cyclic loading is dependant on multiple factors, for instance, the static preload, frequency of the loading, dynamic amplitude, ageing condition, ambient temperature, self-heating, loading history and production instabilities. The results from the test bench for dynamic stiffness (TBDS) are compared with the standard mastercurve Their deviations as well as the need for such measurements for the aforementioned application are discussed along with the effects undetected by the DMTA. The material characterisation approach in the time domain, with a slightly different application in vehicles with an internal combustion engine, focused on self-heating caused by dissipated energy during cyclic loading, is presented. Another part of the Gabo Eplexor 500 is the temperature chamber, which, in combination with liquid nitrogen, allows for measurements to be taken in a temperature range from −150 to 500 ◦ C
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