BOA creates custom mechanical bellows designs to meet the requirements of specific automotive, on-road and off-road applications for exhaust, on-engine and intercooler systems. The company uses finite element analysis software to simulate the ability of proposed bellows designs to decouple the engine motion from the rest of the system. The company then builds a prototype of the proposed design that the customer installs on a vehicle for testing at the proving grounds, capturing data from accelerometers, strain gauges and displacement sensors.
The primary purpose of physical testing for BOA is to validate the critical tradeoff between static manufacturing/assembly offset and dynamic range. The exhaust flex joint has a certain amount of flexibility, or dynamic range, which is needed to accommodate the relative motion of the engine and the exhaust system. However, the initial variation in alignment between the engine and exhaust system, called the static offset, takes up a certain amount of that dynamic range. Physical testing is needed to determine the dynamic range required by the vehicle’s operating envelope to ensure it is within the flex hose’s dynamic range.
Physical testing is also performed to determine the fatigue life of the flex joint on this particular vehicle. The required life of the flex joint might be 150,000 miles, yet there is rarely time to drive the prototype for this full distance. In any case, the life of the flex joint is determined not by how many miles the vehicle is driven but by the number and magnitude of severe loads it receives, such as when the vehicle goes over a pothole. The amount of damage produced by these events is estimated by driving a prototype with the flex joint installed over potholes, Belgian blocks, or other hazards designed to generate severe loads on the flex joint. The loads from each event are recorded by the sensors.
The damaging events are converted to stresses and strains. The vehicle OEM determines a duty cycle that defines how many of each of these damaging events the vehicle is expected to see during its warranty life. The test data is compressed and accelerated to generate a damage profile that corresponds to the OEM’s duty cycle and is used as input for a fatigue analysis that predicts the life of the flex joint.
BOA selected nCode software to streamline its engineering test data analysis because of its ability to handle the complete process within a single environment and its wide range of specialized tools for both test data and FE fatigue analysis.
BOA also switched from its previous fatigue analysis software to nCode DesignLife which integrates with GlyphWorks to enable test data analysis and CAE fatigue analysis in one environment. BOA is able to accurately predict the failure location by using capabilities in DesignLife such as hot spot detection in 3D, stress distribution in 3D, and virtual strain gauge analysis.
BOA engineers take advantage of GlyphWorks’ capability to utilize test data to perform designed experiments to evaluate fatigue life as a function of design parameters such as the diameter of the flex hose. This approach is performed with DesignLife and can be used to improve the existing design without having to run additional RLDA. BOA engineers have also written scripts that evaluate each potential design combination for manufacturability so only designs that can actually be built are evaluated.
Engineers have developed a custom process within GlyphWorks to generate accelerated drive files for a 6 DOF simulation used to test the part without having to install it in a prototype vehicle and run it on the proving ground. This approach can be used after RLDA is performed on a vehicle to evaluate other flex hose designs without having to re-run the RLDA.
High frequency data acquisition is also performed using a microphone inside the passenger cabin to evaluate the impact of the flex joint on noise/vibration/harshness (NVH). BOA uses GlyphWorks to process the data and perform order analysis, which involves matching the accelerometer data to the speed of the motor and makes the data much easier to interpret.
American BOA, incorporated in 1956, is member of the Stutensee, Germany based globally operating BOA Group. Organized in 3 business divisions: Automotive, Industrial and Aerospace, BOA offers a broad range of flexible metal solutions for pipeline systems conveying gases or fluids under severe pressure and temperature conditions. With more than 100 years of experience and 20 subsidiaries or major shareholdings across the world, BOA has become one of the technology leading groups in this particular industry. BOA automotive engineering centers in Germany and in the United States develop specific customized flexible joints and expansion joints for exhaust system, EGR and Oil return lines for engines and mini-bellows for high pressure fuel injection systems which compensate for movements, thermal expansion and decouple vibrations in a reliable way.