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Design for Durability

Course Overview

Design for durability is a technical concept class aimed at helping you design durable products. This course explores the steps necessary to approach product design, development, analysis and testing from the perspective of durability. 

Class time is split between lectures and hands-on sessions where you will put the concepts into action using nCode and ReliaSoft software. Case studies are shared to highlight practical applications of theory.

Course Objectives

  • Understanding the methods, terms and metrics used in durability
  • Knowing when to apply particular tools during the product development cycle and the associated benefits and drawbacks of each
  • Implementing best practices required to make your product meet life cycle targets 

Course Agenda

Duration: 3 Days

  • Introduction to Durability
    • Common product failure modes
    • Designing to improve durability
    • Setting durability requirements and goals
  • The Importance of In-Service Loading
    • Understanding and quantifying in-service usage conditions
    • Field testing of systems, subsystems, and components
    • Measuring load, temperature, acceleration, etc. using data acquisition hardware
      • Transducer selection
      • Sampling rates
      • Data quantity
    • Assessing and improving the quality of measured data
    • Digital signal processing and loads analysis
  • Structural Response
    • Experimental stress analysis techniques
    • Analytical finite element (FE) stress analysis techniques
    • Understanding the difference between static and dynamic response
    • How welds and other joining methods change lives and failure modes
  • Material Behavior
    • Material testing with durability in mind
    • Material response under fatigue loading
    • Characterizing material fatigue behavior
    • Creating stress-life (SN) and strain-life (EN) curves
    • Factors that influence material fatigue characteristics
  • Fatigue Life Estimation
    • The roadmap to fatigue life analysis
    • Analyzing fatigue in different life regimes:
      • Short life
      • Long life
      • Infinite life
    • Important analysis techniques and inputs
  • Interpreting Fatigue Analysis Results
    • Defining failure
    • Deterministic vs. probabilistic views of life
    • Understanding the statistical significance of life predictions
  • Correlating Analytical vs. Actual Durability Life
    • Gaining confidence in analytical modelling
    • Methods of correlating analytical vs. test
    • Correlation bounds and statistical significance
    • Improving modelling techniques based on physical measurements
  • Validation Testing
    • Physical testing to verify product life
    • Testing systems, sub-systems, and components
    • Methods of defining test specifications:
      • Cyclic testing
      • Time domain
      • Frequency domain
    • Uniaxial vs. multiaxial loading
    • Test acceleration methods:
      • Fatigue damage equivalence
      • Reducing test duration

Who Should Attend?

The course is aimed at engineers and managers involved in structural durability, loads collection, fatigue life estimation, and validation testing. As the course is conceptual in nature and not software-focused, it is suitable for both software users and the broader engineering community. Engineering analysts will learn more about the durability-related tasks they are responsible for. Other engineers and managers will learn key points about the durability concepts and analyses they interact with.

It is assumed that attendees are familiar with material behavior and general structural mechanics, typical of most practicing engineers.

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