Finite Element Analysis and Optimization of Intercooler Bracket Cracking

Aiming at the cracking problem of the intercooler bracket during the road durability process, the natural frequency and road spectrum of the bracket were tested firstly, then input to finite element model and thus the modal and forced vibration were analyzed. It was concluded that the resonance between the natural frequency of the intercooler bracket and the road excitation in the Y direction was the main reason for the cracking of the intercooler bracket. By adding the number of bolted connection between the intercooler bracket and the frame, the first modal of the intercooler bracket could be increased. The intercooler bracket optimization scheme has successfully passed the mode test, bench test and road durability test, and the cracking fault is also solved. The fault rectification idea provides a rapid and efficient method for the crack rectification of automobile bracket in the future.