To Investigate the Failure in Sensor Assembly Due to Temperature Variational Loading, and to Provide Optimum Material Solution to Avert This Failure

Abstract

<div class="section abstract"><div class="htmlview paragraph">Engineering, automotive and consumer products include several components, which are connected to each other for their operational purpose and thus form assemblies. Sensors, which are usually formed by assembling several components with each other, have become an integral part of the systems around the world. The components forming these assemblies are made up of various materials like polymers, metals, metal alloys, composites etc. They are connected to each other and then are usually over molded by a thermosetting material which firmly holds these components so that no relative motion is possible among them. Testing was done on a similar speed sensor assembly. When the assembly was mounted in the test rig and step wise temperature variations were applied on it to represent operational loads, failure observed in the assembly in the form of multiple cracks at different locations. This paper investigates the reasons for failure and provides optimal material solution to avert the failure. Initial testing was followed by Finite Element Analysis, which verified these multiple failure locations. By carefully observing the FE analysis results, it was identified that the reason for failure was the substantial difference between the expansion of certain components, particularly at high temperatures. With the extensive research in the area of thermosetting and thermoplastic materials, and with the subsequent parametric study with the help of FE analysis, the optimal material combination was found which in turn led to avert the failure. Subsequent testing with the above identified optimal material combination validated the results given by FE analysis and no further failure was observed. This work enabled in establishing efficient product development process by reducing multiple loops of testing.</div></div>