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D4.1 Effect of manufacturing on fatigue - Abstract

This report presents the effect of manufacturing procedure on the fatigue performance of mechanical components within the framework of WP4. The report is focused on metallic materials loaded in the high-cycle fatigue regime which is most relevant for automotive components. Three important manufacturing procedures have been studied: shear cutting, cold forming and welding. In the report it is shown experimentally that all three routes have a significant negative effect of the fatigue life.
The main focus of the report is the effect of shear cutting, which is the mechanism at trimming of edges of sheet metal and punching of holes; both being very important in the automotive industry. After an extensive experimental campaign, including characterization of cut edges, the cutting procedure is modelled using the Finite Element Method and thereafter used in a fatigue assessment simulation.
For both cold forming and welding it is discussed how such effects should be implemented into the numerical analysis tool for fatigue failures. Finite element simulations of cold forming are a mature technology and results from those simulations can directly be imported into fatigue simulations. Simulations of welding, on the other hand, is very complex with several effects to account for. Hence, a simplified approach is suggested before a complete simulation framework for welded materials is developed in the same way as for cut materials.