Component Level Failure Analysis of Mounting Strap Joint Fitted on Vehicle Engine Exhaust After-Treatment System

Abstract: Exhaust Gas Processors (EGP) or Exhaust After Treatment Systems (EATS) are usually mounted on vehicle chassis or engine body with the help of mounting straps due to its ease of installation. It is prescribed for any industry to manufacture an optimized design of strap joint and duly test it before making an entry to the market. There is no standard method available to be followed by the industry for strap validation at an earlier stage. Most of the strap joint designed and tested based either on MAST test (done in the later stages) or on the experience. So, to test the strap joint at an earlier stage there is a need to design a component level strap joint validation method with a goal to assess the durability of strap joint vulnerable to fatigue failures due to vibration over-amplification in a bracketed after-treatment assembly while able of detecting any design flaws and eliminating or reducing numbers of potential test induced failures. The objective of this work is to define and document a systematic approach for component level strap joint validation method used to mount after treatment system components. Due to geometrical complexity and nature of material, geometrical nonlinearity and material nonlinearity were considered in the analysis. Also, for getting the most realistic results contact nonlinearity was also considered. And finally, out of various approaches investigated, an approach which was able to replicate failures in a more exact manner comparable to assembly level test was recommended as the component level strap validation method.