Rear Axle Housing Research Articles

Finite Element Analysis on Fatigue Failure Prediction of a Rear Axle Housing of Vehicle Based on Cosmos

On the basis of analyzing the typical operating conditions of a vehicle model, 3D model of the rear axle housing was formed by using the Solidworks software, and the stress, strain and the fatigue life of the housing were obtained by using of Cosmos software with the method of finite element analysis. In the effect of alternating stress, the rear axle housing was found existing crack defects. The results showed that the rear axle housing life cycle was improved to over 5.0×105 and satisfied the design requirement. Results provided from tests were compared with the analyses also. It indicated that the proposed method of finite element analysis was a good and efficient method to predict the fatigue life of rear axle housing, which can provide reference for the design of that rear axle housing.

Analysis on Low Amplitude Loading Fatigue Life Strengthening of the Rear-Axle Housing in a Farm Transport Vehicle

Experimental studies were carried out on real rear-axle housing in a farm transport vehicle to investigate the influence of low amplitude preloading on structure life，in order to explore increase potential of rear-axle housing in a farm transport vehicle fatigue life. It is proved that a strengthening area exists in low amplitude loading area. Fatigue lives of rear-axle housings have been increased in some extent with preloading within this area. It can make fatigue life double at most. Based on physical tests, the best strengthening load region of rear-axle housing in a farm transport vehicle was estimated. It provides some technical supports for increasing fatigue life of real rear-axle housing.

Fatigue failure fault prediction of truck rear axle housing excited by random road roughness

A premature fatigue failure that occurred prior to the expected load cycles during the vertical fatigue tests of a truck rear axle housing prototype was studied. A seven degree of freedom dynamic model of truck was presented and vibrating equations on automobile as a whole was also built based on the model. Random road roughness data in time history that is generated by random phase method were applied to vibration differential equations to acquire dynamic load imposed on the rear axle housing. Fatigue failure of the rear axle housing finite element model was predicted after the dynamic load was imposed on it. The simulation results showed that there were premature fatigue failure regions at Banjo transition of the rear axle housing. Results provided from tests were compared with the analyses. The simulation results were same as the fatigue tests. Design enhancement solutions were proposed to increase the fatigue life of the housing according to the simulation and test results. Key words: Fatigue failure, finite element analysis, automobile dynamics, solid axle, rear axle housing.

Research on the New Compound Technology of Integral Seamless Housing of Rear Axle

In order to save energy and material, and reduce productive costs, in accordance with the geometrical characteristics of rear axle housing of trucks, the redesign of integral product with new technology was completed, and then, two kinds of forming technology were developed. Afterwards, rear axle housing of light trucks was formed by adopting hydraulic bulging and neck-spinning, and the housing of heavy trucks by adopting hot mechanical expanding and hot neck-spinning with the tube. The research of this paper has practical value and results in great economic returns.

Structural Optimization Design of Rear Axle Housing Excited by Dynamic Load

In order to obtain structural optimization design of rear banjo axle housing, a seven degree of freedom dynamic model of vehicle was presented. Based on the model, vehicle vibrating equations were presented. Random phase method was used to generate C grade road surface irregularity of time history that applied to vibrating equations to acquire dynamic load imposed on the banjo axle housing. A detailed CAD model of the housing was developed by using of UG software. The finite element model of the housing was built, and the stress and strain of the housing were obtained by using of ANSYS Workbench software. The mathematical model of optimal design was constructed and analyzed based on the result of finite element method. The optimization result shows that the weight of banjo axle housing can be reduced under satisficing the stress and strain condition that excited by dynamic load.

Virtual Fatigue Test of Auto Parts Based on Non-Structural Road Driving Simulation

Non-Structural road driving test is a key part of fatigue and durability tests for vehicles such as the construction machines and ATVs. Combining a theoretic road-tyre dynamic model with some real vehicle design parameters, the responses of the wheel axle under different non-structural road conditions were estimated conveniently. The responses can be taken as inputs for a virtual test-rig simulation, and the responses of every part on the test object are obtained separately. Fatigue life is predicted under the finite element circumstance, and the reliability and durability are concluded. Comparing with the real road-driving test, the virtual fatigue test method above can significantly reduce the test period. This method is used to predict the fatigue life of the rear axle-housing in construction machines, the accuracy of the method is verified by a corresponding real bench test.

Fatigue failure prediction of a rear axle housing prototype by using finite element analysis

A premature failure that occurs prior to the expected load cycles during the vertical fatigue tests of a rear axle housing prototype is studied. In these tests, crack mainly originated from the same region on test samples. To determine the reason of the failure, a detailed CAD model of the housing was developed. Mechanical properties of the housing material were determined via tensile tests. Using these data, stress and fatigue analyses were performed by finite element method. Fatigue crack initiation locations and minimum number of load cycles before failure initiation were determined. Results provided from tests were compared with the analyses. Design enhancement solutions were proposed to increase the fatigue life of the housing.

Rigid–plastic finite element analysis of hydroforming process and its applications

An finite element method (FEM) program, HydroFORM-3D, for the analysis and design of tube hydroforming processes, has been developed, and then applied to the hydroforming process for an automobile rear axle housing and subframe. This paper includes the theoretical background of the program. By using the developed program and the ductile fracture criterion, the process design for the straight tube hydroforming process of a rear axle housing, is presented. The potential failure site for the rear axle housing predicted by the numerical simulation is consistent with experimental results. The preform design of the typical pre-bent tube hydroforming process of forming a subframe, which concentrates on the determination of initial diameter of the tubular blank, is suggested.

Bursting failure prediction in tube hydroforming processes by using rigid–plastic FEM combined with ductile fracture criterion

The most common failure in tube hydroforming is the bursting failure due to excessive thinning of large deformation. To evaluate the forming limit of hydroforming processes, the Oyane's ductile fracture integral I was introduced and calculated from the histories of stress and strain according to every element by using the rigid–plastic finite element method. The region of fracture initiation and the forming limit for three hydroforming processes, such as a tee extrusion, an automobile rear axle housing, and a lower arm under different forming conditions are predicted in this study. Also it is shown that the material parameters used in the ductile failure can be obtained from the experimental forming limit diagram. From the results, the prediction of the bursting failure and the plastic deformation for the three hydroforming examples demonstrates to be reasonable so that this approach can be extended to a wide range of practical tube hydroforming processes.

Analysis and design of hydroforming process for automobile rear axle housing by FEM

An FEM program, HydroFORM-3D, for the analysis and design of tube hydroforming processes, has been developed by modifying and adding some subroutines to the previous rigid-plastic finite element program, and then applied to the hydroforming process for an automobile rear axle housing. This paper includes the theoretical background of the program development. Through a numerical simulation, an optimum process is proposed to meet the practical requirements, which shows the efficiency of the numerical simulation. Two types of hydroforming dies are analyzed by numerical simulation. The sliding-type die has the drawback of a possibility of buckling, whereas the fixed-type die causes bursting failure. The thickness distribution of the final product is affected not only by the types of die, but also by the loading paths. The potential failure site for rear axle housing predicted by the numerical simulation is consistent with the experimental results. The values of maximum axial compression force for the first and second hydroforming processes are also in good agreement with experimental data. To manufacture a sound automobile rear axle housing without failure, it is better to use the sliding-type die and it is also critical to maintain a suitable hydraulic pressure level.

96/01736 Assessment of combined TCO/metal rear contact for thin film amorphous silicon solar cells

An FEM program, HydroFORM-3D, for the analysis and design of tube hydroforming processes, has been developed by modifying and adding some subroutines to the previous rigid-plastic finite element program, and then applied to the hydroforming process for an automobile rear axle housing. This paper includes the theoretical background of the program development. Through a numerical simulation, an optimum process is proposed to meet the practical requirements, which shows the efficiency of the numerical simulation. Two types of hydroforming dies are analyzed by numerical simulation. The sliding-type die has the drawback of a possibility of buckling, whereas the fixed-type die causes bursting failure. The thickness distribution of the final product is affected not only by the types of die, but also by the loading paths. The potential failure site for rear axle housing predicted by the numerical simulation is consistent with the experimental results. The values of maximum axial compression force for the first and second hydroforming processes are also in good agreement with experimental data. To manufacture a sound automobile rear axle housing without failure, it is better to use the sliding-type die and it is also critical to maintain a suitable hydraulic pressure level.

On the Fatigue Strength of Welded Rear Axle Housing for Automobiles

On the Fatigue Strength of Welded Rear Axle Housing for Automobiles