Standards and Approaches For Ball Joint Durability Testing

Standards and Approaches for Ball Joint Durability Testing
Tuesday, May 6, 2008 Stuttgart, Germany
Paul Carroll Mechanical Engineer GRV Component Test
Dr. Eric Little Applications Engineer GRV Component Test
Ball Joint Overview

Ball Joint Basics
Inner Ball Joint
Common ball joint applications Types of ball joints
Upper Ball Joint Lower Ball Joint
Tie Rod End
Ball Joint Components
Types of Ball Joints
May 6, 2008
Testing Expo -- Stuttgart, Germany
SAE J193 Ball Joint Tests

In general, J193 tests are uni-axial . . . . . . except for Assy Fatigue/Heat Treat.
J193 Ball Joint Tests
Impact Strength Yield Tensile Load Rotation & Oscillation Torque Axial End Movement Cam-Out Strength Assy Fatigue and Heat Treat Pull-Out/Push-Out Strength
MTS Capabilities

A multi-axial test system is required.

May 6, 2008 3 Testing Expo -- Stuttgart, Germany
J193 Endurance Load Requirements

5.2.4 Ball Stud and Socket Assembly Fatigue and Heat Test 5.2.4.1 Objective To determine fatigue and wear characteristics of ball stud and socket assemblies. 5.2.4.2.2 Phase II Test Endurance Load: To correlate the cycle life of the assembly for the average load to which the assembly will be subjected in application and environment, with life in actual use . . .
The Goals: - Determine ball joint loads experienced during service life. - Translate those loads into an easily-reproducible laboratory test.
May 6, 2008
J193 Loading and Cycle Life Criteria

Comments on Loading/Cycle Life from J193
The loading use in the test procedures should be as representative as

possible in magnitude and direction with loads encountered in the design application. Using a vehicle . . . a program loading procedure can be utilized to obtain a more realistic loading assessment.
May 6, 2008
Focus: Front Lower Control Arm
May 6, 2008
What is the Loading Environment?
Input Loads Moments
Attachment Loads Moments
May 6, 2008
What is the Loading Environment?

Strain Gauged Ball Joint
May 6, 2008
Test Planning Peak Valley Slicing

Reduced DOFs No
Is this a Multi-axial Case?
Yes
No
Is Reproduction of frequency content Important?
Yes
No
Is there a linear relationship between any axis of loading?
Yes
No
Sinusoidal or Block Cycle Time History Simulation or PSD repro
Is Reproduction of Frequency content important
Yes
May be able To use PV Slicing Method

May 6, 2008 9
Time History Simulation
Peak Valley Slice Technique

Multi-axial case
Solid Strut
Long
Lat
Vert
Phasing between Vertical, Lateral & Long Inputs is critical; frequency reproduction is not important
Peak Valley Test Methodology

Peak Valley Slice Test Method
Identify Peak/Valley pairs in multi-channel data.
May 6, 2008
11

5 kph Braking events
Raw Time History = 40 sec
Longitudinal Force
PV Time History = 10 sec
Benefit: Speed up slow events


Pothole Strike Reproduction
Raw Time History
Longitudinal Force
PV Time History
Benefit: Slow down fast events

Peak Valley Slicing

Benefits of PV Slicing
Applies accurate max/min displacements to specimens. Ensures phase relationships between peak loads are maintained. Can reduce test time. More representative damage accumulation than block cycle testing.
When PV Slicing is not applicable
Elastomeric or components with frequency-dependent characteristics.
May 6, 2008
14
Test Planning Time History

Reduced DOFs No
Is this a Multi-axial Case?
Yes
No
Is Reproduction of frequency content Important?
Yes
No
Is there a linear relationship between any axis of loading?
Yes
No
Sinusoidal or Block Cycle Time History Simulation or PSD repro
Is Reproduction of Frequency content important
Yes
May be able To use PV Slicing Method

May 6, 2008 15
Time History Simulation
What is Remote Parameter Control?

Remote Parameter Control (RPC) is an advanced simulation technique used to repeatedly replicate and analyze in service vibrations and motions of a specimen using a dynamic mechanical system in a controlled laboratory environment.
.e.g. Accelerometer
2. PARAMETER
3. CONTROL
Control of Amplitude Distributions Spectral Densities Multi-axial Phase Relationship
1. REMOTE
May 6, 2008
16
The RPC Process Typical Correlation

Iterations example response data
Simulation results are typically evaluated in the time, frequency, and statistics domains; often times fatigue is also used.
MTS Standard Ball Joint Test System Examples
Four Axis Test
Three Axis Test

(Inner Ball Joints)
Five Axis Test
May 6, 2008
18
May 6, 2008
19

Standards and Approaches For Ball Joint Durability Testing

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Standards and Approaches for Ball Joint Durability Testing

Tuesday, May 6, 2008 Stuttgart, Germany

Paul Carroll Mechanical Engineer GRV Component Test

Dr. Eric Little Applications Engineer GRV Component Test

Ball Joint Overview

Common ball joint applications Types of ball joints

Upper Ball Joint Lower Ball Joint

Tie Rod End

Ball Joint Components

Types of Ball Joints

Testing Expo -- Stuttgart, Germany

SAE J193 Ball Joint Tests

A multi-axial test system is required.

J193 Endurance Load Requirements

Testing Expo -- Stuttgart, Germany

J193 Loading and Cycle Life Criteria

The loading use in the test procedures should be as representative as

Testing Expo -- Stuttgart, Germany

Focus: Front Lower Control Arm

Testing Expo -- Stuttgart, Germany

What is the Loading Environment?

Input Loads Moments

Attachment Loads Moments

Testing Expo -- Stuttgart, Germany

What is the Loading Environment?

Testing Expo -- Stuttgart, Germany

Test Planning Peak Valley Slicing

Is Reproduction of frequency content Important?

Is there a linear relationship between any axis of loading?

Is Reproduction of Frequency content important

May be able To use PV Slicing Method

Time History Simulation

Testing Expo -- Stuttgart, Germany

Peak Valley Slice Technique

Peak Valley Test Methodology

Identify Peak/Valley pairs in multi-channel data.

Testing Expo -- Stuttgart, Germany

Peak Valley Slice Test Method

PV Time History = 10 sec

Benefit: Speed up slow events

Peak Valley Slice Test Method

Benefit: Slow down fast events

Peak Valley Slicing

Elastomeric or components with frequency-dependent characteristics.

Testing Expo -- Stuttgart, Germany

Test Planning Time History

Is Reproduction of frequency content Important?

Is there a linear relationship between any axis of loading?

Is Reproduction of Frequency content important

May be able To use PV Slicing Method

Time History Simulation

Testing Expo -- Stuttgart, Germany

What is Remote Parameter Control?

Testing Expo -- Stuttgart, Germany

The RPC Process Typical Correlation

MTS Standard Ball Joint Test System Examples

Four Axis Test

Three Axis Test

Five Axis Test