Fatigue Life Prediction for the Steel Passenger Car Wheel in the Dynamic Cornering Fatigue Test
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PRODUCTION SECTION FATIGUE LIFE PREDICTION FOR THE STEEL PASSENGER CAR WHEEL IN THE DYNAMIC CORNERING FATIGUE TEST Z. C. Dong,a,1 X. F. Wang,a X. G. Zhang,b W. P. Lou,a
UDC 539.4
Y. N. Huang,c and M. Zhongc This study aims to establish an effective method for predicting the fatigue life of an automotive wheel in the accelerated dynamic cornering fatigue test. The test was simulated by linear transient dynamic finite element analysis, in which a rotating force of constant magnitude was applied to the moment arm tip to simulate the rotational bending effect on the wheel, with the wheel being fixed. Furthermore, transient strain histories of the elements were obtained and the critical elements with the largest amplitudes in their respective steady radial strain histories were found. The steady radial strain histories of all the critical elements were processed based on the local stress-strain approach, and the shortest simulated fatigue lives were taken as the predicted wheel fatigue lives. The predicted fatigue life was in good agreement with the average real-world test life of the investigated wheel. Keywords: automotive wheel, rotational bending, finite element analysis, transient strain history, fatigue life prediction. Introduction. In the automotive industry, wheels are viewed as critical components of the suspension system, which must support significant static and dynamic loads encountered in service [1]. The dynamic cornering fatigue test of automotive wheels is a standard SAE test that simulates the dynamic bending effects on the wheel during vehicle operation [2]. Figure 1 shows the test system applied by Dongfeng Automotive Wheel Co., Ltd., in which the wheel is mounted on a rotating table via clamps, with the moment arm fixed to the outer wheel mounting pad with bolts, and a constant force applied at the tip of the moment arm by the loading actuator and bearing, thus imparting a constant rotational bending moment on the wheel [3]. The assessment of durability and fatigue of wheels early in the design stage plays an important role in the development of automotive wheels [4]. Attention was also paid to the simulation of the test, based on which the wheel’s fatigue strength can be assessed, its life predicted, and design improvements made even before the first prototype of the wheel is made in the design stage [5]. The methods used to simulate the dynamic cornering fatigue test of the wheel via finite element analysis and different fatigue life prediction methods were studied by a number of researchers [6, 7]. However, these studies provided no sufficient details for achieving good accuracy, which is decisive for obtaining a realistic prediction of fatigue life [3]. This paper represents a continuation of the research a
School of Vehicle and Mobility, Tsinghua University, Beijing, China ([email protected]). b Dongfeng Automotive Wheel Co., Ltd., Shiyan, China. cSAIC GM Wuling Automobile Co., Ltd., Liuzhou, China. Translated from Problemy Prochnosti, No. 4, pp. 184 – 205, July – August, 2020. Origi
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