Abstract
The durability of safety-critical automotive vehicle steel structures has been observed to be influenced significantly by the condition of the component’s cut-edge properties. The importance of the mechanical cut-edge properties on structural durability has been observed due to surface imperfections generated during the cutting process. These then become the preferred initiation sites for fatigue cracks due to the increased intensity of stress applied to a structure. The current work outlines the development of an improved finite element (FE)-based life prediction method, based on strain-life fatigue data of S355MC steel cut-edges. The resulting best method of predicting fatigue lives of cut-edges using the Coffin–Manson method has been determined as providing the best means for predicting the durability of high strength steel components. This process has been validated using a bespoke laboratory test component representative of those in automotive chassis and suspension assemblies. The outcome of this work is that it allows increased reliance on FE life predictions rather than extensive physical laboratory testing.
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