A proposed innovative approach for predicting the torsional moment capacity of half-shaft based on static FEM

Abstract

The torsional moment capacity of the automotive half-shaft is a crucial design parameter, and the utilization of induction hardening can enhance this capability. This paper presents the development of a comprehensive static finite element simulation model and a three-layer gradient distribution model of material property for the half-shaft based on its actual heat treatment state. A torque prediction model was developed for the torsional moment capacity of the half-shaft based on the torque-angle curve derived from the static finite element analysis. This model accurately and quickly predicts the torque value at which the half-shaft will break during the torsional test. In contrast with the current continuum damage mechanics method, this approach requires a reduced number of material factors and has a lower computing cost. Furthermore, the accuracy of the prediction results in three distinct groups of half-shafts reaches 94 %, 97 %, and 99.6 %. This approach can provide guidance for the design and enhancement of half-shafts, potentially replacing or minimizing the need for torsion testing of automotive half-shafts. It has the potential to minimize the duration of the product development cycle and lower the associated costs. It can also be applied to different drive shafts, demonstrating excellent adaptability and extensive applicability.