The use of nCode software for test and CAE in the product development processes of AL-KO

Since 1931, AL-KO have been manufacturing premium, high quality components used in the automotive, commercial and leisure industry. The extensive range of AL-KO’s chassis components premium accessories and spare parts are engineered to last.

Challenge

Capture and secure the fatigue life of all components and products developed by AL-KO through an accurate virtual and physical testing process. AL-KO needs to be able to make precise predictions regarding product life, performance, durability, and warranty while reducing the overall time and effort going into the development process.

Solution

AL-KO established a development and testing process that includes the use of nCode GlyphWorks for data analysis and nCode DesignLife for fatigue simulation, enabling a cost efficient, fast, and reliable development and production of new components.

Injection molding analysis performed by Moldex3D on a seat adjustment.

Results

less prototypes
extended durability
easy identification of critical locations

reduced costs for tooling
reduced development time

more precise tests
easy generation of test rig signals

“With just a few simple FE-analysis based changes to the design, we were able to extend the durability of our 13“ axle by more than 5 times, having the same costs and material conditions as previously used. nCode DesignLife helps us to identify critical locations, and nCode GlyphWorks helps us to generate test rig signals easily. With a combined use of nCode software for both test and CAE analysis, we created opportunities in product development AL-KO previously didn’t have, and we could reduce prototypes, physical testing effort, costs, and development time.“

Wolfgang Hildensperger, responsible for FEM and fatigue analysis at AL-KO

Want to learn more about the featured products?

Test data processing and durability analysis

nCode GlyphWorks is a data processing system that contains a powerful set of pre-defined tools for performing durability analysis and other insightful tasks such as digital signal processing. Designed to handle huge amounts of data, GlyphWorks provides a graphical, process-oriented environment that contains leading analysis capabilities for saving both time and money in environmental qualification and product validation.

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CAE-based fatigue analysis

nCode DesignLife is an up-front design tool that identifies critical locations and calculates realistic fatigue lives from leading finite element (FE) results for both metals and composites. Design engineers can go beyond performing simplified stress analysis and avoid under- or over-designing products by simulating actual loading conditions to avoid costly design changes.

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