Methodical procedure for a surrogate model based fatigue calculation to support the design process of eBike drive units

In this paper, a method is developed to consider multiaxial load spectra and their variation in a computationally efficient local fatigue calculation procedure. This method is based on an FE data-based surrogate model and is intended to support the simulation-based product design process. To demonstrate their application and necessity, a case study on the design of eBike drive units is presented. For this purpose, the general requirements for the design of eBike drive units as well as the fundamentals of multiaxial fatigue analysis and surrogate modeling are outlined. In addition, a validation process of the surrogate model and its use for fatigue calculation is presented and discussed.