This conference paper was submitted for presentation at the NAFEMS World Congress 2025, held in Salzburg, Austria from May 19–22, 2025.

Abstract

In finite element analysis and simulation, correlating test data (gage data, acceleration data, etc.) to load cases used in simulations is crucial for developing reliable models that accurately represent real-world conditions. This process involves examining the data , model calibration techniques, and reliability of the data and analysis model. By converting strain gage data into meaningful load cases, engineers can better simulate real-world conditions, leading to improved predictive models and design validation. Processing of statistical data and applying that data to load case development is the first step to having an accurate model that matches real life. In this process, test data is applied to real-world scenarios using various data manipulation techniques, simulation tools, and validation processes. These tools can be used in tandem to determine the load cases and operations that are most damaging. Understanding and calculating these damaging operations is a critical aspect of engineering analysis. Finding where the damage is generated during operations means identification and analysis of load cases that lead to material fatigue, structural failure, and other forms of damage. By leveraging strain gage data to calculate where the damage is coming from, engineers can develop more accurate models and focus on the largest contributors, rather then just running all the load cases, to predict and mitigate these damaging effects, improving the durability and safety of designs. This data can also be applied in real world problems so that updates are made focusing on the source of the issue rather than trying to fix a symptom. Integration of gage data and test data into engineering simulations is essential to bridge theoretical models with real-world applications. This presentation will demonstrate the benefit of this process and improvements in design performance using several case studies. These real-world applications demonstrate the practical benefits of accurate test correlation and load case development. They provide insight into best practices and approaches to applying strain gage data to projects. Using these methods, the accuracy of iterations is improved, accelerating the design process, and reducing the need for additional testing. With a comprehensive overview of test correlation and load case development, the identification of damaging operations, and the application of this data to real-world scenarios can take analysis beyond just analysis but starts to simulate real world solutions. By bridging the gap between theoretical analysis and practical application, engineers can enhance the reliability and performance of their designs, leading to safer and more efficient solutions.