Finite Element Simulation of Electromagnetic Shaker for Environmental Test

The Environmental Test group at KCNSC performs various mechanical tests to evaluate the production lifetime of components. The majority of these tests are performed on an electromagnetic (EM) shaker. An EM shaker is a device that converts electrical energy to mechanical vibrations using the principles of electromagnetism. This vibration testing is highly useful for field testing components that are routinely subjected to repetitive vibrations and shocks. In order to facilitate a reduction in unnecessary testing time, simulation of the shaker using finite element modeling (FEM) is an invaluable tool to predict real-world outcomes. Full dynamic characterization of the shaker as well as its interaction with adapters and test fixtures is difficult to capture but is nonetheless fundamental to understanding the response of a unit undergoing test. Inputs to achieve reliable predictive simulation results require accurate design, a proper understanding of coupling behavior, and precise test article definition. At KCNSC, we are performing modal and dynamic analyses using our FEM model of an electromagnetic shaker. This abstract intends to examine some of the design challenges our team has faced such as model creation, boundary condition definition, and response matching to test specifications. We will also examine future challenges we are working to overcome which could allow for better prediction of input parameters prior to simulation.