Experimental Research on Manson–Coffin Curves for the Frame Material of an Unconventional Vehicle

Abstract

The submitted research paper describes the fundamental findings in terms of multiaxial fatigue of the basic material EN AW6063 and its welds for implementation in the frame design of an unconventional vehicle. It also includes a briefly-presented conceptual design of a technical solution for optimizing the functionality of a steering mechanism in a patented unconventional vehicle, designed by the authors to increase the cornering stability of a vehicle–tricycle. The most important part of this article is the description of the ongoing research and the results of multiaxial fatigue (bending–torsion combination) of the structural material for the construction of the vehicle frame. The research in this area is important due to the increased load on the frame during operation caused by the unconventional steering mechanism. The measured and constructed Manson–Coffin curves indicate that the use of material EN AW6063 is possible for this vehicle in terms of multiaxial stress. This also applies to the material affected by the technology in the frame production (TIG welding). A higher fatigue of the basic material was observed at a 90° phase shift. The difference between the 0° and 90° phases practically makes up approximately 10 to 15% of the difference in the cycle numbers with the same deformation amplitude. At the same time, the measured results show that the phase shift between loads will not play such an important role in welded joints of aluminum alloy EN AW6063. When comparing the dependences with a constant deformation amplitude in bending and in torsion, it can be said that the bending stress will react more to even a small change in the deformation amplitude. Bending has been proven to be the more dominant component of the total deformation amplitude in multiaxial tests. In terms of low-cycle multiaxial fatigue (up to 5 × 105 cycles), a higher fatigue of the basic material is found in comparison with the weld. At lower deformation amplitudes, a higher fatigue of the welded material is detected.

Utilizing Dynamic Analysis in the Complex Design of an Unconventional Three-Wheeled Vehicle with Enhancing Cornering Safety

“…It was specifically designed to apply both flexural and torsional loads, as well as their combination. The authors have previously published some information about this testing device in [2,7,8,19,25,26]. The research conducted on the fatigue life of the welded structural material EN AW 6063 confirmed the suitability of the chosen structural material [8].…”

“…The authors have previously published some information about this testing device in [2,7,8,19,25,26]. The research conducted on the fatigue life of the welded structural material EN AW 6063 confirmed the suitability of the chosen structural material [8]. In this article, our objective is to emphasize additional crucial aspects that should be considered during the development of the testing device and the analysis of the results obtained from measuring the multiaxial fatigue life of the E3-kolka frame material.…”

“…This understanding led to the development of a new front-steered wheel suspension system (Figure 1b) that allows for both wheel displacement and rotation, thus increasing the lever arm of the gravitational force and consequently the stabilizing moment. The approach to achieving the desired mobility capabilities was published by the authors in [2,[7][8][9]. This represents the second step in the process of theoretical improvement.…”

“…The final design proposal for the frame is preceded by a substantial effort invested in determining the physical properties of the construction material. The authors addressed this issue through extensive research described in detail in [2,7,8,19]. The yield strength of the EN AW 6063 material was experimentally determined using a tensile test, resulting in an average value of 247 MPa.…”

“…Given the diverse combinations of loads encountered in practical scenarios, it becomes necessary to assemble multiple multiaxial fatigue testing devices capable of simulating these load combinations. Consequently, one of the aims of this study, in line with the referenced works [2,7,8,19,27], is to establish a comprehensive testing methodology for evaluating the fatigue life under the combined cyclic loading effects of bending and torsion.…”