Fatigue life prediction of a heavy vehicle steel wheel under radial loads by using finite element analysis

The origin of fatigue failure that occurs on the air ventilation holes of a newly designed heavy commercial vehicle steel wheel in dynamic radial fatigue tests is studied. In these tests, all of the test samples failed in the same regions. The cause of this damage was studied via finite element analysis. In order to determine the reason of the fatigue failure, stress analysis was performed via the finite element method. In this way, stress concentrated regions, where fatigue failure is expected, were determined. Mechanical properties of the wheel material were determined by tensile tests and hardness measurements. The fatigue life of the damaged wheel was estimated using the stress–life (S–N) approach, utilising the ultimate tensile strength of the processed wheel material and the Marin factors determined for the critical regions. To extend the life of the wheel disc and delay the onset of fatigue, design enhancement solutions were applied.

► The premature failure of a steel wheel that occurs during the course of radial fatigue tests is studied.
► Crack initiation occurs at the most stress concentrated regions of the air ventilation holes.
► Stress life approach gives a reasonable estimate of the fatigue life of the steel wheel.