F2010C163
Fatigue Life Prediction Method of Wire Harness System in the Automotive Vehicle's Door
In this study, wire, bundle and ass'y level of the wire harness system are investigated for the fatigue life prediction using both finite element method (FEM) and experimental analysis. To obtain stress-life (S-N) histories of the componential wires of the system, AVSS wires are prepared and applied repeated bending motion using developed fatigue life equipment. Equivalent model of the wire from rule of mixture theory is used for the simplification of the analysis. Contact conditions among the wires, taping conditions, optimized composition of wires, effects of the number of wires in the bundle are derived through the bundle level test and bundle numerical analysis. Wire and bundle level results are adopted for the ass'y level analysis. For the ass'y level analysis, real wire harness system including bundle and gromat is numerically modeled and applied contact condition between wire and gromat with real opening motion. The fatigue life more than 300,000 cycle of the ass'y is obtained from the FEM, and it is confirmed that the result has good agreement with the experimental result.
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