Abstract
This paper details the failure analysis of a wheel hub from a student designed Formula SAE® race car that fractured at the roots of the rim finger attachment region. The wheel hub was identified to be manufactured from a rolled Al 6061 alloy. The experimental characterization included fracture surface analysis and microstructural analysis using scanning electron microscopy, as well as compressive stress–strain testing and micro-hardness testing to determine its mechanical properties. Analysis of the fractured surfaces of the hub revealed beach marks and striations, suggesting a fatigue failure. A kinematic model was developed to determine wheel hub loadings as defined by the car driving history. Detailed loads calculated from a kinematic equilibrium model and material properties obtained from the experiment results were used in a finite element model to simulate the stress distribution and fatigue life of the wheel hub. The wheel simulation results were consistent with the failure mode determined from the fractography study.
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