| Non-linear spring plates, used in a variety of products, are selected based on characteristics of their mechanical behavior and generally fail in fatigue. From a design perspective, it is highly desirable to possess the capability to calculate both spring plate force-displacement behavior and spring plate fatigue life. To this end, a finite element model was developed for predicting both loading behavior and fatigue life. Material characterization was conducted to inform the modeling process. A simulation of the spring plate manufacturing process was developed, motivated by the strong influence of residual stresses and hardening on spring plate behavior. Results of the manufacturing simulation were used to model actuation of the spring plate. Finally, output from the simulation of spring plate actuation was used to calculate spring plate fatigue life. Accounting for manufacturing processes proved critical in obtaining accurate results. This methodology has the potential to be applied to other punched or blanked geometries. |
