In this paper, a novel algorithm for the determination of Walker damage in loaded disc springs is presented. The algorithm takes a 3D-scan of a disc spring, measured residual stresses, material parameters, and spring loads as inputs. It outputs a distribution of Walker damage over the surface area of the input disc spring. As the algorithm allows a fully automated determination of the Walker damage, it can be used by disc spring manufacturers to reduce the working time spent on this task by specialized engineers significantly. Compared to spreadsheet applications using analytical formulas and finite element models using idealized geometry, this approach offers a superior description of the stress states in disc springs.
Keywords: Abaqus Scripting; FEA; automation; disc springs; fatigue; real geometry.