Abstract
Drive axles are an essential component for power transmission in any automobile. It transfers the power from the differential to the hub of the wheels which drives the vehicle. The axles are subjected to torsional stresses due to the torque from the differential and the resisting torque present due to the frictional resistance from the ground on the wheels. Hence, they are prone to torsional failures under fatigue with and without shock loading. In this paper, a comprehensive engineering failure analysis of the failed drive axle shaft of material EN 24-T, custom designed for a 200kg BAJA SAE all-terrain vehicle was performed. Destructive, non-destructive testing and material analysis along with finite element simulations using Ansys were carried out to better understand the nature and cause of the failure. Failure analysis data hints at the flaws in design considerations and scanning electron microscopy (SEM) images reveal the formation of bainitic microstructures within the component due to improper heat treatment which lowers the ultimate tensile strength of the material.
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