Browse Publications Technical Papers 2020-01-1232
2020-04-14

Effect of Flange radius and width on the Fatigue Life of wheel hub under Cornering Loads 2020-01-1232

Automotive Wheel Hub is a safety critical component. Integrated Wheel hub design is improved from 1st generation to 3rd generation to meet the durability targets with less weight. Lateral loading is critical parameter for designing wheel hub. Cornering test is performed at vehicle level to evaluate wheel hub. Cornering test has combination of three types of tracks. In Wheel hub design, flange radius and flange width are two important design parameters to meet the durability life for cornering loads. We have considered the combination of different flange radius and flange width to understand the effect of these two parameters on wheel hub fatigue life. These three-wheel hubs are tested till failure and life scatter is plotted. Strain data is acquired at flange radius on wheel hub for all cornering test tracks. Using Wheel Force Transducers (WFT), Forces and moments are acquired at wheel center for all cornering test tracks. Duty cycle is derived from measured loads. FE model of Wheel end simulation contains Wheel hub, Wheel rim, Knuckle, drive shaft and wheel nut. FE Analysis is performed at every 360-angle loading (measured peak lateral and vertical load) for each track considering geometric and boundary(contacts) nonlinearities. Bolt preload is also considered. Using fatigue life from FEMFAT and derived tire rotations(repeats) from NCODE, cornering test cycles are calculated using Miner's Rule. Strain & failure mode are correlated between test and CAE. Fatigue life scatter in test and CAE are comparable. This new methodology is established for evaluating the wheel hub in future.

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