In this paper, fatigue life assessment of a tensioner is studied through dynamic load analysis, stress analysis, and stress-life fatigue analysis approach. Tensioner is a critical part of an automotive front end accessory drive system, providing pre-tension to the belt. The front end accessory drive systems are responsible for transmitting power from the crankshaft to the accessory components. Due to the engine pulsation, components of the accessory drive including the tensioner are subjected to dynamic loads leading to fatigue failure. The fatigue life assessment of a mechanical component highly depends on loading, geometry, and material properties. In addition, the dynamic behavior of the front end accessory drive is complicated due to coupling between several modes of vibrations in belt, pulleys, and the tensioner arm. Duo to the complexity of the parameters involved and complicated dynamics, the fatigue life analysis of FEAD components is a challenging task. This paper includes three main parts, namely stress analysis, fatigue properties prediction, and life estimation. The dynamic analysis of a generic front end accessory drive system is performed in order to obtain effective loads on the tensioner. Stress state for the tensioner in case of different applied loading conditions is performed via a series of Finite Element (FE) analyses, and the critical region of the part is determined. Finally, fatigue life is estimated through strain-life approach. Modest work has been found in this area providing a comprehensive solution to the fatigue life investigation of power train components. The present study offers a comprehensive modeling approach which predicts the automative tensioner lifetime. The lifetime of any FEAD system components can be determined using the developed fatigue life prediction approach.

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