Customer had spent years developing contact simulation models in the FEA of their locking mechanisms. However, variation in finishing quality and lubrication of the contact surface of finished parts forced wide variation in the torque experience by these mechanisms, which introduced uncertainty into the fatigue life prediction that was difficult to describe with computational models.
Using SmartUQ, the customer was able to zero in on key Coefficient of Friction (COF) parameters that could be used to explain the torque variation seen in physical testing. They were then able to develop calibrated distributions for the COF parameters that encapsulated the variation in torque seen in testing.
The distributions developed for the key FEA COF parameters were used to validate the model’s ability to capture the variation seen in physical testing. With this validated model, the supplier can examine the torque performance of current and future designs due to variation introduced by manufacturing. This will give them better life predictions of their manufactured parts and improve their ability to design dependable locking mechanisms.
