Investigation of the similarity between physical tests and fatigue simulation of flange yoke made of C45 E material used in cardan shafts

Abstract

AbstractThis study is focused on experimental and numerical estimation of the fatigue life of a flange yoke. The material's stress‐life (fatigue) curve (S−N curve) for axial loading is constructed using specimens extracted from actual flange yokes. The torsional fatigue lives of components are determined by torsional fatigue tests of the complete cardan shafts. Simulation of the cardan shaft model including the flange yoke is carried out in Catia V5 R6 2016 software, which is then transferred to Altair Hyperworks 2017 software for the stress analyses. To predict the number of cycles to failure, the results are transferred into nCode 2018 DesignLife analysis module. An aim is to employ the stress‐life curves as input in numerical calculations and finite element analyses to minimize the costly and time‐consuming experimental work. The results show that physical testing and analysis results are in accordance when S−N curve of actual component material, as well as surface roughness factors measured from real component surface affecting fatigue life are incorporated into the analysis.