Numerical analysis of wheel cornering fatigue tests

Abstract

In automotive engineering, the wheels are one of the most critical components and their function is of vital importance n human safety. The cornering fatigue test is one of the traditional durability tests for wheel prototype verification. In this paper, a bi-axial load–notch strain approximation for proportional loading is proposed to estimate the fatigue life of a passenger car wheel during the cornering fatigue test under plane stress conditions. The elasto-plastic strain components are calculated analytically using the total deformation theory of plasticity. The input for the load–notch strain analysis is the measured or calculated plastic strain state at the notch together with the materials stabilised cyclic stress–strain curve evaluated with unnotched tension specimens. The damage accumulation is based on the Palmgren–Miner rule. The methodology is implemented in a program called “Metal Fatigue Prediction and Analysis” (MFPA). The life prediction of a passenger car wheel during the cornering fatigue test is performed. The results of the analysis is compared with two cornering tests on the same design. The result is very encouraging and the application of the developed MFPA program provides time and the cost savings in the analysis of wheel cornering fatigue tests.