Factors affecting the accuracy of durability estimates in the design of automotive V-belt pulleys using finite element analysis

Abstract

In this study, factors influencing the accuracy of the durability estimation for an automotive V-belt pulley were investigated using finite element analysis (FEA). The bolt load, centrifugal load, and stress history were considered for fatigue life calculations, and their effects on the accuracy of the durability estimation were analysed. The stress history of a pulley that experienced a compressive load induced by belt tension, bolt load, and centrifugal load was determined by performing a consecutive static FEA on the rotating pulley. An estimation of the V-belt pulley fatigue life was based on a damage analysis of 36 load steps. Durability tests for the pulleys were then performed to verify the analysis results. The analysis and experimental results were closely correlated. Additional analyses were performed using the same procedure by isolating each factor and studying its effect on the durability estimation. The results revealed that the bolt load in the pulley analysis was not negligible in improving the accuracy of the analysis, and showed that more stress history must be used for the fatigue life calculations.