Accelerated Fatigue Life Estimation of An Axle Housing

Year 2025, Volume: 9 Issue: 1, 60 - 70, 31.03.2025

Fatma Dilay Aksoy , Olcay Dağcı , Oğuzhan Çamoğlu , Onur Balcı

https://doi.org/10.30939/ijastech..1401496

Abstract

In this study, the fatigue test time of an axle housing was aimed to decrease by increasing the testing load without having permanent deformation on the housing. In this concern, the deformation values of the banjo zone of a heavy-duty commercial vehicle welded complete axle housing under static loads were measured with a dial indicator, the elastic behavior of the housing was observed, and the yield limit was tried to be determined. The axle housing underwent vertical fatigue tests under specified elastic loading circumstances, and the housing's fatigue life was examined under progressively higher loading conditions. In parallel with the static and fatigue tests, the stress and displacement values in the axle housing were obtained with the finite element analysis program ANSYS and verified with the test results. Load conditions, test configurations and fatigue life results are described in detail in the article. Considering the preliminary study [1] results, this study went one step further and tried to obtain the optimum load-life relationship that can be applied as accelerated vertical fatigue test condition for verification of an axle housing. In this way, it is aimed to reduce the time spent on fatigue tests and to provide economic benefits by performing tests in fewer cycles with a higher load.

Keywords

Axle housing, finite element analysis, stress, strain, elasticity, yield, S-N curve, accelerated fatigue life

Ethical Statement

I hereby declare that this study is an original study; that I have acted in accordance with the principles and rules of scientific ethics at all stages of the study, including preparation, data collection, analysis and presentation of information; that I have cited sources for all data and information not obtained within the scope of this study and included these sources in the bibliography; that I have not made any changes in the data used, and that I comply with ethical duties and responsibilities by accepting all the terms and conditions of the Committee on Publication Ethics (COPE). If, at any time, a situation contrary to this statement I made about the study is detected, I agree to all moral and legal consequences that may arise.

Thanks

The authors would like to thank Ege Endüstri ve Tic. A.Ş. for providing all kinds of support for our work with test center facilities, computer and engineering software. We would also like to thank DergiPark and International Journal of Automotive Science and Technology for giving us the opportunity to publish this study and for making it available to the interested parties.

Bir Diferansiyel Kovanının Elastik Davranışının Belirlenmesi ve Hızlandırılmış Yorulma Ömrünün İncelenmesi

Abstract

Bu çalışmada, bir ağır ticari araca ait kaynaklı komple diferansiyel kovanının statik yükler altında banjo bölgesi deformasyon değerleri ölçülerek kovanın elastik davranışı gözlemlenmiş ve akma sınırı belirlenmeye çalışılmıştır. Diferansiyel kovanının belirlenen elastik yükleme koşulları aralığında kalarak düşey yorulma testleri gerçekleştirilip kovanın kademeli artan yükleme koşullarında yorulma ömrü incelenmiştir. Statik ve yorulma testlerine paralel olarak sonlu elemanlar analiz programı ANSYS® ile diferansiyel kovanındaki gerilme ve deplasman değerleri elde edilerek test sonuçları ile doğrulanmıştır. Yük koşulları, test konfigürasyonları ve yorulma ömür sonuçları makalede detaylı olarak anlatılmıştır. Öncül çalışma [1] sonuçları da dikkate alınarak bu çalışma ile bir adım daha ileri gidilmiş ve bir diferansiyel kovanında hızlandırılmış düşey yorulma testi ile doğrulama şartlarında uygulanması gereken optimum yük-ömür ilişkisi elde edilmeye çalışılmıştır. Bu sayede daha fazla yük ile daha az çevrimde test gerçekleştirilerek yorulma testlerinde harcanan zamanın azaltılması ve ekonomik yarar sağlanması hedeflenmiştir.

Keywords

Diferansiyel kovanı, sonlu elemanlar analizi, gerilme, gerinim, esneklik, akma, S-N eğrisi, hızlandırılmış yorulma ömrü

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