Research on Fatigue Life of the Automobile Differential Case (original) (raw)
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Fatigue Analysis of Front Axle for Automobile Heavy Motor Vehicle
International Journal for Research in Applied Science & Engineering Technology (IJRASET), 2023
The axles in a system must bear the weight of the vehicle as well as any cargo weight. The front axle beam is one of the major parts of vehicle suspension system and it houses the steering assembly as well. About 35 to 40 percent of the total vehicle weight is taken up by the front axle. Corrosion, wear and fatigue are the main causes of failure of mechanical parts. Main failure form of front axle beam is fatigue damage. The axles serve to transmit driving torque to the wheel, as well as to maintain the position of the wheels relative to each other and to the vehicle body. Therefore, the research on the fatigue life has important value. So, proper design and optimization of front axle is extremely crucial to Fatigue strength. The paper focuses on design, analysis and optimization of front axle. The approach in this research paper has been divided into two steps. The First step involves design of front axle by Analytical method. For this, types of forces loads with the help of CAD UNIGRAPHICS NX9.Second step involved further Pre-processing using ANSYS bench work 15.0 and post processing with the help of ANSYS bench work NCODE. Also the experimentation test performed and compared with FEA results.
Fatigue life evaluation of an Automobile front axle
An axle is a central shaft for rotating wheel or gear. It is the important part of the vehicle. The axle maybe fixed to the wheels, rotating with them or fixed to its surrounding, with the wheels rotating around the axle. Basically there are two types of axles, front and rear. Frontal axle is important and critical part of the vehicle as it carries steering load, impact load, engine load and most of the vehicle curb weigh (60%). Hence it is important to study the design and structural integrity of front axle and how it will impact on the engine life and driver. The present work is to focus on structural analysis of front axle using FEA approach blended with the classical approach for preliminary design considerations and loading conditions. The approach of the problem is divided into two parts, primarily the design considerations of fatigue load condition and preliminary design of frontal axle. Secondly, finite element analysis and simulation of frontal axle is carried out to verify the preliminary design considerations at essential stage using FEA software.
Design and Fatigue Optimization of Drive Shaft
International Journal for Research in Applied Science & Engineering Technology (IJRASET), 2021
This work aims towards the design and optimization of the drive shaft as there is increasing demand for weight reduction in an automobile vehicle. The drive shaft is basically a torque transmitting element which transmit the torque from the differential gearbox to the respective wheels. In general, the drive shafts are subjected to fluctuating loads as the torque requirement changes according to the road conditions. Due to this, the drive shaft should be designed considering fatigue failure. The Maruti Suzuki Ertiga model is chosen for design and optimization of the drive shaft. For the fatigue life predicting of the drive shaft, the S-N curve approach is used. Furthermore, the inner diameter of the shaft is varied to obtain the optimized diameter of a hollow shaft which can withstand these fluctuating loads without failure. Along with fatigue life prediction, the natural frequency of the hollow shaft is also calculated. Furthermore, the parametric analysis is carried out of fatigue FOS, Von mises stress, weight and natural frequency of the shaft by varying the diameter ratio of the hollow shaft, and the nature of variation of these parameters are plotted in their respective graphs. The design is validated by performing FEA analysis for each case of a hollow shaft using Ansys software. Finally, from the FEA analysis we conclude that the optimized dimensions of the hollow drive shaft are safe.
Front axle of heavy duty truck is the important component of vehicle and needs good design under the various loading conditions of the complete vehicle. Aim of the project is to stress analysis and predict the life of front axle for vertical, and vertical and braking loading case. The fatigue life of front axle is generally estimated by stress life approach and strain life approach method. Front axle beam assembly was modeled in the NX cad software. Meshing and Stress analysis is performed by ANSYS workbench and fatigue analysis is performed by NCODE design life ANSYS tool under different loading cases. Fatigue life of axle obtained by FEA method is more than 2 x 10 5 cycles, which is considered as safe for vertical loading case. Similarly, Fatigue life of axle obtained is more than 4 x 10 3 cycles, which is considered as safe for vertical and braking loading case. The max stress region is below spring pad of axle for vertical loading and in the goose neck of axle for vertical and braking loading case.
DESIGN AND ANALYSIS OF DRIVE SHAFT FOR HEAVY DUTY TRUCK
Drive shafts in commercial heavy duty vehicle are subjected to cyclic loads due to variation in the torque demanded by the varying road loads. Cases of failure of the drive shaft of heavy duty trucks have been reported, which provides an opportunity to investigate the issue. In this project an attempt has been made on prediction of fatigue life of the drive shaft using FEA technique. The load spectrum acting on the drive shaft is calculated for specified terrain. Structural analysis was carried out on the FE model of drive shaft, and potential areas of high stress concentration are obtained. Von Mises stress, fatigue damage, fatigue life, factor of safety and total deformation are the results of fatigue analysis. It was observed that from the static analysis that the roots of the splines are the areas of high stress concentration. The fatigue analysis revels that the drive shaft fails in the region of high stress concentration as expected. The fatigue life of the component is found to be infinite for design pay load. The life of the drive shaft for 40% and 50% over load is 69806 kilometers and 20564 kilometers respectively. The present work can be used in automobile industry as a reference for predicting life of any component, in the drive line of the automobile subjected to non constant amplitude loading.
Determination of the Fatigue Life of the Vehicle Construction Based on Strength Calculations
The article is divided into three parts. Except the foundations of theoretical knowledges about the fatigue life, the design of the breakdown truck body construction for a particular vehicle is also described in initials. In the second part the stress analysis of this construction is analyzed by finite element method (FEM). Based on this, at the end of the thesis, the fatigue life time is evaluated and compared with the experimental. Keywords: fatigue service lifetime, breakdown truck body construction, Rule EEC 55, Abaqus CAE, finite element method (FEM)
Validation of A356T6 automobile wheel fatigue strength using the finite elements method
European Mechanical Science
In this study, A356T6 wheel bending fatigue test limits determined using the finite element methods and compared to experimental test results. In experimental test, zinc-glycerin was applied front surfaces of wheels to obtain fatigue detects. Short and long cycle bending fatigue tests (200.000 and 1.800.000 respectively) were performed. Simulation model was created in Ansys by defining A356 S-N curve. Simulation performed has been with test parameters. According to simulation results, the crack starts 225.000 cycle in short-test and 2.000.000 cycle in long -test. According to the results, it has been revealed that the experimental and analysis data are parallel to each other.
Fatigue Analysis of Drive Shaft
The main objective of this analysis is to investigate the stresses& deflections of drive shaft subjected to combine bending & torsion. Then checking for fatigue life as well as comparing the results with analytical calculations to verify accuracy of the results. Drive shaft is a critical component used in paper converting machines. It carries a load of two vacuum rollers weighing around 1471N and rotates at 1000 rpm, also subjected to reaction force of knife cutter and gears. This shaft has key slots and at the area of change in cross sections giving rise to localize stress concentration. Hence there is a scope of analyzing this part to predict its fatigue life and damage. Keywords: Fatigue Analysis, Shaft stress analysis, FEM analysis, shaft failure analysis
Fatigue Analysis of a Commercial Vehicle Axle Body using the Short Crack Model
2000
ABSRACT Using a commercial vehicle forged axle body made of a low-alloyed steel as an example, the present paper demonstrates the usefulness of the Short-Crack-Model for the fatigue analysis and the design optimization of engineering components during their early developmental stage. The cyclic material input data used were approximated by means of the Uniform Material Law based only on monotonic
A Review on Fatigue Life Prediction of a Heavy Vehicle Steel Wheel by using finite Element Analysis
International Journal of Engineering Sciences & Research Technology, 2014
This review reports the state of the art in modeling chemical and physical processes of Wheels have vital importance for the safety of the vehicle and a special care is needed in order to ensure their durability. The development of the vehicle industry has strongly influenced the design, the material selection and the manufacturing processes of the wheels. The wheels loading manner is a complex one; further improvement and efficient wheel design will be possible only if their loading will be better understood. In this paper, the review about various papers which is based on analyzed with the finite element method, using the different loading test. The static stresses are studied in order to find the zones with higher stress concentration and to suggest the better design solution.