Research Article
BibTex RIS Cite

Investigation of the Main Factors Affecting the Fatigue Life of Structural Casting Parts in Heavy Commercial Vehicle Brake Systems

Year 2024, Volume: 12 Issue: 1, 378 - 387, 25.03.2024
https://doi.org/10.29109/gujsc.1367887

Abstract

In the study, factors affecting the fatigue life of the bridge, which is one of the main casting components of an air disc brake used in heavy commercial vehicles, were investigated to enhance its service life. Considering all the boundary conditions affecting the brake under real operating conditions, a two-level factorial experimental design method was used for the three factors predicted to have the most effect on fatigue life and two different levels were determined for each factor and specimens were produced. Structural analyses were conducted using the finite element method to identify critical regions with high stresses on the part. In the tests, to capture the moment of crack initiation, a tripwire was applied to the areas where the stress was high and the part failure was expected, as determined by numerical methods. Prepared test samples were subjected to fatigue testing until mechanical damage occurred and cycles where cracks formed were analysed in detail. As a result of the analysis, the two factors found to have the greatest impact on the fatigue life of the bridge were identified as "pearlite ratio" and the "combination of caliper orientation and bridge casting cavity". It was observed that the fatigue life of bridge samples with a high perlite ratio increased up to 3.1 times compared to low-perlite samples and when an appropriate combination of caliper orientation and bridge casting cavity was selected, it increased up to 3.4 times.

References

  • [1] Limpert, R. “Brake design and safety Third Edition”, SAE; 2011.
  • [2] Day, Andrew J., and David Bryant. “Braking of road vehicles”. Butterworth-Heinemann, (2022).
  • [3] Güleryüz, İ. C. & Yılmaz B. "Ağır Hizmet Araci Fren Diski Soğuma Davranışının İncelenmesi." Gazi University Journal of Science Part C: Design and Technology 8.4 (2020): 936-947.
  • [4] Tagesson, Kristoffer. “Truck steering system and driver interaction”. Chalmers Tekniska Hogskola (Sweden), 2014.
  • [5] Seetharamu, S., Thimmarayappa Jagadish, and Ravindra Malagi. “Fatigue, Durability, and Fracture Mechanics Proceedings of Fatigue Durability India 2019.” Proceedings of Fatigue Durability India (2019).
  • [6] Di Cocco, Vittorio, et al. "Damaging micromechanisms characterization in a ferritic-pearlitic ductile cast iron." Frattura ed Integrità strutturale 8.30 (2014): 62-67.
  • [7] Čanžar, Predrag, Zdenko Tonković, and Janoš Kodvanj. "Microstructure influence on fatigue behaviour of nodular cast iron." Materials Science and Engineering: A 556 (2012): 88-99.
  • [8] D’Agostino, Laura, Vittorio Di Cocco, and Francesco Iacoviello. "Overload effects on fatigue cracks in ferritic-pearlitic ductile cast irons." Procedia Structural Integrity 2 (2016): 3369-3376.
  • [9] Benedetti, M., V. Fontanari, and D. Lusuardi. "Effect of graphite morphology on the fatigue and fracture resistance of ferritic ductile cast iron." Engineering Fracture Mechanics 206 (2019): 427-441.
  • [10] Vantadori, Sabrina, et al. "Fatigue behaviour assessment of ductile cast iron smooth specimens." International Journal of Fatigue 152 (2021): 106459.
  • [11] “Maintenance Manual no. MM-0350 ELSA 195/225 Reaction Beam Air Disc Brake”; (2009).
  • [12] Güleryüz, İ. C. & Yılmaz B., “Ağır hizmet araçlarında kullanılan disk fren kaliper yuvasının yapısal analizi ve deneysel doğrulaması” 4th International Mediterranean Science and Engineering Congress (IMSEC 2019) Antalya 2019, (2019).
  • [13] Tyagi, Parshant. Finite Element Analysis of Innovated Design of Racing Brake Calipers. Diss. Wichita State University, College of Engineering, Department of Mechanical Engineering, 2006.
  • [14] Tirovic, M., et al. "Structural analysis of a commercial vehicle disc brake caliper." Proceedings of the Institution of Mechanical Engineers, Part D: Journal of Automobile Engineering 226.5 (2012): 613-622.
  • [15] Sergent, Nicolas, Marko Tirovic, and Jeronimas Voveris. "Design optimization of an opposed piston brake caliper." Engineering Optimization 46.11 (2014): 1520-1537.
  • [16] Güleryüz, İbrahim Can. "Lightweight design of a torque plate of Z-cam drum brake for heavy duty vehicles." International Journal of Automotive Science and Technology 3.2 (2019): 42-50.
  • [17] Tekbaş, U., Güleryüz, İ.C., Ağır Hizmet Araçlarında Kullanılan Hidrolik Disk Fren Kaliper Yuvasının Topoloji Optimizasyonu. 3rd International Symposium on Automotive Science and Technology, (2023).
  • [18] ISO 945-1, “Microstructure of cast irons — Part 1: Graphite classification by visual analysis”, (2018).
  • [19] ISO 945-2, “Microstructure of cast irons — Part 2: Graphite classification by image analysis”, (2017).
  • [20] ISO 945-3, “Microstructure of cast irons — Part 3: Matrix structures”, (2018).
  • [21] ISO 945-4, “Microstructure of cast irons — Part 4: Test method for evaluating nodularity in spheroidal graphite cast irons”, (2019).
  • [22] Taylor, D., and J. F. Knott. "Fatigue crack propagation behaviour of short cracks; the effect of microstructure." Fatigue & Fracture of Engineering Materials & Structures 4.2 (1981): 147-155.
  • [23] Mathews, Paul G. “Design of Experiments with MINITAB”. Quality press, (2004).
  • [24] Anderson, Virgil L., and Robert A. McLean. Design of experiments: a realistic approach. CRC Press, (2018).

Yapısal Döküm Parçaların Yorulma Ömrünü Etkileyen Ana Faktörlerin Ağır Ticari Araç Fren Sistemlerinde İncelenmesi

Year 2024, Volume: 12 Issue: 1, 378 - 387, 25.03.2024
https://doi.org/10.29109/gujsc.1367887

Abstract

Çalışmada, ağır ticari araçlarda kullanılan havalı disk frenin ana döküm parçalarından biri olan köprünün servis ömrünün arttırılabilmesi için yorulma ömrüne etkiyen faktörler incelenmiştir. Fren parçasına, gerçek çalışma koşullarında etki eden tüm sınır koşulları göz önüne alınarak, yorulma ömrüne en çok etki edeceği öngörülen üç faktör için iki kademeli faktöriyel deney tasarımı yöntemi kullanılmış ve her bir faktör için iki farklı seviye belirlenerek numune üretimleri gerçekleştirilmiştir. Parça üzerindeki gerilmelerin yüksek olduğu kritik bölgelerin belirlenmesi amacıyla sonlu elemanlar yöntemi kullanılarak yapısal analizler gerçekleştirilmiştir. Testlerde, çatlağın ilk oluştuğu anda yakalanması için sayısal yöntem ile belirlenen, gerilmenin yüksek olduğu ve parçaların kırılması beklenen bölgelere tuzak teli uygulanmıştır. Hazırlanan test numuneleri mekanik hasar meydana gele kadar yorulma testine tabi tutulmuş ve çatlak oluşan çevrimler detaylı analiz edilmiştir. Analiz sonucunda köprü parçasının yorulma ömrüne en fazla etki eden iki faktör sırası ile “perlit oranı” ve “kaliper yönü ile köprü döküm gözünün kombinasyonu” olarak bulunmuştur. Perlit oranı yüksek olan köprü numunelerinin yorulma ömürlerinin, düşük olan numunelere göre 3,1 kata kadar; uygun kaliper yönü ve köprü döküm gözü kombinasyonu seçildiği durumda ise 3,4 kata kadar arttığı tespit edilmiştir.

References

  • [1] Limpert, R. “Brake design and safety Third Edition”, SAE; 2011.
  • [2] Day, Andrew J., and David Bryant. “Braking of road vehicles”. Butterworth-Heinemann, (2022).
  • [3] Güleryüz, İ. C. & Yılmaz B. "Ağır Hizmet Araci Fren Diski Soğuma Davranışının İncelenmesi." Gazi University Journal of Science Part C: Design and Technology 8.4 (2020): 936-947.
  • [4] Tagesson, Kristoffer. “Truck steering system and driver interaction”. Chalmers Tekniska Hogskola (Sweden), 2014.
  • [5] Seetharamu, S., Thimmarayappa Jagadish, and Ravindra Malagi. “Fatigue, Durability, and Fracture Mechanics Proceedings of Fatigue Durability India 2019.” Proceedings of Fatigue Durability India (2019).
  • [6] Di Cocco, Vittorio, et al. "Damaging micromechanisms characterization in a ferritic-pearlitic ductile cast iron." Frattura ed Integrità strutturale 8.30 (2014): 62-67.
  • [7] Čanžar, Predrag, Zdenko Tonković, and Janoš Kodvanj. "Microstructure influence on fatigue behaviour of nodular cast iron." Materials Science and Engineering: A 556 (2012): 88-99.
  • [8] D’Agostino, Laura, Vittorio Di Cocco, and Francesco Iacoviello. "Overload effects on fatigue cracks in ferritic-pearlitic ductile cast irons." Procedia Structural Integrity 2 (2016): 3369-3376.
  • [9] Benedetti, M., V. Fontanari, and D. Lusuardi. "Effect of graphite morphology on the fatigue and fracture resistance of ferritic ductile cast iron." Engineering Fracture Mechanics 206 (2019): 427-441.
  • [10] Vantadori, Sabrina, et al. "Fatigue behaviour assessment of ductile cast iron smooth specimens." International Journal of Fatigue 152 (2021): 106459.
  • [11] “Maintenance Manual no. MM-0350 ELSA 195/225 Reaction Beam Air Disc Brake”; (2009).
  • [12] Güleryüz, İ. C. & Yılmaz B., “Ağır hizmet araçlarında kullanılan disk fren kaliper yuvasının yapısal analizi ve deneysel doğrulaması” 4th International Mediterranean Science and Engineering Congress (IMSEC 2019) Antalya 2019, (2019).
  • [13] Tyagi, Parshant. Finite Element Analysis of Innovated Design of Racing Brake Calipers. Diss. Wichita State University, College of Engineering, Department of Mechanical Engineering, 2006.
  • [14] Tirovic, M., et al. "Structural analysis of a commercial vehicle disc brake caliper." Proceedings of the Institution of Mechanical Engineers, Part D: Journal of Automobile Engineering 226.5 (2012): 613-622.
  • [15] Sergent, Nicolas, Marko Tirovic, and Jeronimas Voveris. "Design optimization of an opposed piston brake caliper." Engineering Optimization 46.11 (2014): 1520-1537.
  • [16] Güleryüz, İbrahim Can. "Lightweight design of a torque plate of Z-cam drum brake for heavy duty vehicles." International Journal of Automotive Science and Technology 3.2 (2019): 42-50.
  • [17] Tekbaş, U., Güleryüz, İ.C., Ağır Hizmet Araçlarında Kullanılan Hidrolik Disk Fren Kaliper Yuvasının Topoloji Optimizasyonu. 3rd International Symposium on Automotive Science and Technology, (2023).
  • [18] ISO 945-1, “Microstructure of cast irons — Part 1: Graphite classification by visual analysis”, (2018).
  • [19] ISO 945-2, “Microstructure of cast irons — Part 2: Graphite classification by image analysis”, (2017).
  • [20] ISO 945-3, “Microstructure of cast irons — Part 3: Matrix structures”, (2018).
  • [21] ISO 945-4, “Microstructure of cast irons — Part 4: Test method for evaluating nodularity in spheroidal graphite cast irons”, (2019).
  • [22] Taylor, D., and J. F. Knott. "Fatigue crack propagation behaviour of short cracks; the effect of microstructure." Fatigue & Fracture of Engineering Materials & Structures 4.2 (1981): 147-155.
  • [23] Mathews, Paul G. “Design of Experiments with MINITAB”. Quality press, (2004).
  • [24] Anderson, Virgil L., and Robert A. McLean. Design of experiments: a realistic approach. CRC Press, (2018).
There are 24 citations in total.

Details

Primary Language Turkish
Subjects Numerical Methods in Mechanical Engineering, Material Design and Behaviors
Journal Section Tasarım ve Teknoloji
Authors

Özgün Cem Yılmaz 0000-0002-1222-7718

Bora Güntay 0000-0002-8526-3285

İbrahim Can Güleryüz 0000-0002-2002-6684

Early Pub Date March 22, 2024
Publication Date March 25, 2024
Submission Date October 2, 2023
Published in Issue Year 2024 Volume: 12 Issue: 1

Cite

APA Yılmaz, Ö. C., Güntay, B., & Güleryüz, İ. C. (2024). Yapısal Döküm Parçaların Yorulma Ömrünü Etkileyen Ana Faktörlerin Ağır Ticari Araç Fren Sistemlerinde İncelenmesi. Gazi University Journal of Science Part C: Design and Technology, 12(1), 378-387. https://doi.org/10.29109/gujsc.1367887

                                TRINDEX     16167        16166    21432    logo.png

      

    e-ISSN:2147-9526