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Halfpenny, Andrew; Tahera, Khadija; Thumati, Balaje and Wynn-Jones, Chris
(2024).
Abstract
In a concerted effort to minimise humanity’s adverse impact on our environment, the automotive industry is keen to develop new and innovative solutions for a carbon-neutral future. They therefore face a critical requirement to offer extended warranties on new and relatively unfamiliar technologies such as advanced battery systems. This paper considers how the existing simulation, verification, and validation design process, may be enhanced to offer significant improvements in predicted confidence. Particular attention is paid to simulating the physical fatigue qualification test using a process called ‘virtual testing’. This allows simulation to be better verified using evidence from fewer physical tests. The paper highlights the need for additional low-cost measurements during testing and a need to test to failure. It considers how virtual and physical tests may be integrated into a typical automotive design management process. It demonstrates how these tests mutually benefit one another.