Multi-scale fatigue life prediction method of the A356 wheel considering the effects of casting microstructure

IF 5.7 2区材料科学 Q1 ENGINEERING, MECHANICAL

International Journal of Fatigue Pub Date : 2025-04-11 DOI:10.1016/j.ijfatigue.2025.108977

Shihao Wang , Zhongyao Li , Haibo Qiao , Qinghuai Hou , Decai Kong , Xuelong Wu , Xiaoying Ma , Yisheng Miao , Shuwei Feng , Xiang Ci , Wenbo Wang , Yuling Lang , Shiwen Xu , Junsheng Wang

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Abstract

A356 alloys produced by low pressure die casting (LPDC) typically contain casting defects and non-uniform microstructure. In this study, a multi-scale fatigue prediction method for the automotive wheel considering both hydrogen and shrinkage microporosity and secondary dendrite arm spacing (SDAS) has been developed. A three-dimensional cellular automata (CA) model is used to simulate both dendritic growth and hydrogen microporosity. The database of equivalent diameter of microporosity and casting conditions has been established, and the data is mapped to a structural mesh by an efficient mesh mapping algorithm in order to perform both static and dynamic simulations. The wheel’s cornering fatigue is successfully simulated by taking into account the microstructure features. By combining the high-cycle fatigue test and finite element analysis (FEA), the specific effects of stress concentration due to far-field stress, pore size, and location on fatigue life have been quantified. Based on this method, S-N curves have been derived for different conditions. Finally, a multi-scale fatigue life prediction model for the wheel is developed and the corresponding S-N curves are imported for each node of the model, enabling accurate prediction of the cornering fatigue life of the wheel. This method innovatively proposes integrative optimization of automotive wheel manufacturing process.

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考虑铸造组织影响的A356车轮多尺度疲劳寿命预测方法

低压压铸生产的A356合金通常存在铸造缺陷和不均匀的显微组织。本文提出了一种考虑氢、缩孔、二次枝晶臂间距的汽车车轮多尺度疲劳预测方法。三维元胞自动机（CA）模型用于模拟枝晶生长和氢微孔隙度。建立了微孔等效直径和铸造条件数据库，并采用高效网格映射算法将数据映射到结构网格中，实现了静态和动态模拟。考虑了车轮的微观结构特征，成功地模拟了车轮的转弯疲劳。通过高周疲劳试验与有限元分析相结合，量化了由远场应力、孔径和位置引起的应力集中对疲劳寿命的具体影响。在此基础上，推导出了不同条件下的S-N曲线。最后，建立了车轮多尺度疲劳寿命预测模型，并对模型各节点导入相应的S-N曲线，实现了车轮转弯疲劳寿命的准确预测。该方法创新性地提出了汽车车轮制造过程的一体化优化。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

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来源期刊

International Journal of Fatigue 工程技术-材料科学：综合

CiteScore

10.70

自引率

21.70%

发文量

619

审稿时长

58 days

期刊介绍： Typical subjects discussed in International Journal of Fatigue address: Novel fatigue testing and characterization methods (new kinds of fatigue tests, critical evaluation of existing methods, in situ measurement of fatigue degradation, non-contact field measurements) Multiaxial fatigue and complex loading effects of materials and structures, exploring state-of-the-art concepts in degradation under cyclic loading Fatigue in the very high cycle regime, including failure mode transitions from surface to subsurface, effects of surface treatment, processing, and loading conditions Modeling (including degradation processes and related driving forces, multiscale/multi-resolution methods, computational hierarchical and concurrent methods for coupled component and material responses, novel methods for notch root analysis, fracture mechanics, damage mechanics, crack growth kinetics, life prediction and durability, and prediction of stochastic fatigue behavior reflecting microstructure and service conditions) Models for early stages of fatigue crack formation and growth that explicitly consider microstructure and relevant materials science aspects Understanding the influence or manufacturing and processing route on fatigue degradation, and embedding this understanding in more predictive schemes for mitigation and design against fatigue Prognosis and damage state awareness (including sensors, monitoring, methodology, interactive control, accelerated methods, data interpretation) Applications of technologies associated with fatigue and their implications for structural integrity and reliability. This includes issues related to design, operation and maintenance, i.e., life cycle engineering Smart materials and structures that can sense and mitigate fatigue degradation Fatigue of devices and structures at small scales, including effects of process route and surfaces/interfaces.