A computer simulation of four-point bending fatigue of a rear axle assembly

The bending fatigue test of a rear axle assembly is simulated by using a FE-integrated fatigue analysis methodology. The presented technique is based on local stress–strain approach in conjunction with two critical plane damage parameters. The stress–strain response at a material point is computed with a cyclic plasticity model coupled with a notch stress–strain approximation scheme. Linear elastic FE stress analyses are used in the calculation of local fatigue loading. All computational modules are implemented into the software tool and used in the four-point bending fatigue test simulation of rear axles made of a high-strength alloy steel. In fatigue models, proportional loadings with a static preload are considered, and the effects of residual stresses are neglected. The fatigue test cycles and crack initiation locations are predicted using Smith–Watson–Topper and Fatemi–Socie fatigue damage parameters. Both damage parameters provided conservative test cycle estimates for the test conditions simulated. It is also observed that von Mises stress distributions cannot be used to predict fatigue crack initiation locations while Smith–Watson–Topper critical plane parameter estimated the cracking location suitably. Comparisons with the prototype tests showed the applicability of the proposed approach.

► A numerical methodology based on local stress–strain concept is developed for fatigue analysis. ► Efficient and practical for FE-integrated design analysis in general. ► Four-point bending test of a rear axle is simulated and fatigue test cycles are predicted properly.