Modeling analysis and lightweight design for an axle hub considering stress and fatigue life

Zhang, Cuixia; Dong, Quande; Zhang, Liangxi; Li, Qiang; Shen, Xuehong

doi:10.1177/0036850420929930

Cited by 7 publications

(6 citation statements)

References 22 publications

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“…Local performance optimization will be done only when the local performance does not meet the requirements, such as local heat treatment to improve local strength. Such a design leads to uneven distribution of axle performance and excess local structural performance, which is against the equal-strength principle of mechanical design, and also makes the axle too heavy and wastes costs (Zhang et al , 2020).…”

Section: Introductionmentioning

confidence: 99%

Toward structure optimization for the mobile vehicle system based on multiconstraints

Zhao

Sun

et al. 2023

RIA

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Purpose Vehicle lightweight design has positive implications for reducing energy consumption and abating greenhouse gas emissions. The traditional trailer axle design mainly focuses on the overall performance of the trailer axle. Only when the local performance does not meet the requirements will local performance optimization be done, such as local heat treatment to improve local strength. Such a design results in an uneven distribution of axle performance and excess performance in some local structures. The purpose of this study is to investigate the weight reduction on the premise of ensuring the structural dimensions of the outer surface of the axle remain unchanged and the reliability of the axle. Design/methodology/approach The axle is parameterized by computer aided design, and the optimized axle finite element model based on computer aided engineering is established and verified by taking the eight dimensions of the axle cavity structure which affect the performance as parameters. A genetic algorithm is used to optimize the axle cavity structure size and axle weight based on multiobjective optimization, and eight optimized size parameters of axle cavity structure are obtained. Findings The total weight of the optimized axle of TM1314 is reduced by 10.2 kg, and the weight reduction ratio reaches 10.7%. According to the optimized structural size of the axle, the specimen was trial-manufactured, and the bench tests of stiffness, strength and fatigue life were carried out according to the test requirements of the trailer axle standard (JT/T 475-2002). The test results show that the maximum deformation of the specimen is 2.46 mm, the strength safety factor of the specimen body and the steel plate spring seat are 6.71 and 6.86 and bear the alternating load more than 1.05 × 106 times, which meets the standard of the trailer axle and is better than the original design requirements of the trailer axle. Originality/value In this study, the multiobjective optimization model of the axle is established, the response surface is constructed by the Latin hypercube sampling design method and the optimal solution set is obtained by the multiobjective genetic algorithm. It has been verified by bench tests that it can achieve a weight reduction of 10.7% under the premise of the same structure and size of the outer surface of the axle. The lightweight method based on multiobjective optimization proposed in this paper can provide a reference for the lightweight design of other key vehicle components.

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Section: Introductionmentioning

confidence: 99%

Toward structure optimization for the mobile vehicle system based on multiconstraints

Zhao

Sun

et al. 2023

RIA

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“…Meanwhile, in various fields of mechanical engineering, experts employ the finite element method to optimize the dimensions of mechanical structures in order to reduce weight. 14 – 16 After the structural optimization was completed, many experts 17 , 18 performed fatigue calculations on the structure to verify the reliability of the optimized structure. Some other scholars have modified and optimized the life calculation method in fatigue life analysis in order to obtain more accurate life data.…”

Section: Introductionmentioning

confidence: 99%

Fatigue analysis and optimization design of key components of synthesizing equipment for artificial diamond based on a method of information exchange system

Jia,

Sun,

Chen

et al. 2023

Science Progress

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In this article, a method of information exchange system (MIES) has been proposed to optimize the structure of the hinge sleeve of cubic (HSC), a key component of synthetic diamond. The MIES method integrates static analysis, topology optimization, and fatigue failure analysis. By using this method, the lightweight design of the structure was ensured while meeting the fatigue life requirements. The weight of the optimized model was reduced from 5729.9 kg to 4593.4 kg, and the fatigue life was 1.127E+05, which meets the serviceability requirements. The steps of the method are as follows: First, the model of HSC was established. According to the loading conditions, the basic material data and boundary conditions were set, and the stresses and strains of the HSC were calculated. The optimized region was obtained by topological analysis of the HSC structure using the variable density method. The fatigue life of the model was then calculated by combining the stress life method and the average stress correction method. Simulations were performed using the above method to obtain the six nodes of maximum stress in the HSC. These nodes were used as control points for the structural optimization design. The HSC model was optimized by optimizing the structure in the region of the control variable points. Computational analysis of the optimized HSC model was carried out using the information exchange system. After repeated optimization of the structure of the HSC model, a model with a lightweight design was obtained. The ANSYS simulation results showed that the final mass of the HSC model was reduced by 19.83%. Stress and life were within the design requirements. The information exchange system has better computational performance, feasibility, and reliability compared to traditional theoretical methods.

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“…Combine the reverse modeling technique with the topological optimization method to derive lightweight wheel hubs based on the principles of mechanics by Xu et al [12]. Considering stress and fatigue life, a lightweight design of the axle hub based on ANSYS is studied by Zhang et al [13]. Digital twin of the rotor shaft of a lightweight electric motor during aerobatic loads is studied by Goraj [14].…”

Section: Introductionmentioning

confidence: 99%

Lightweight Design of Special Axle Hub Based on ANSYS Consider Different Working Conditions for Low Carbon

Zhang

et al. 2022

Mathematical Problems in Engineering

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The lightweight design is considered to be of great significance for carbon reduction. Therefore, a lightweight design of a special axle hub is proposed based on ANSYS considering different working conditions. The structure of a special axle hub is identified. The ANSYS Workbench is used to mesh the hub and import the mechanical and physical parameters. Considering full load, emergency turning and braking, and the treatment of constraints and loads, the stress concentration position is obtained, and the lightweight design is carried out. The free vibration analysis and fatigue life prediction of the hub after lightweight design are verified. After the lightweight design, the optimized hub mass is reduced by 7.52%, and its structural stability and strength meet the demands of various working conditions. The application of a lightweight hub reduces CO2 emissions by 49875 kg during the life cycle of the vehicle. This study provides theoretical and methodological support for lightweight design of mechanical parts for low carbon.

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Modeling analysis and lightweight design for an axle hub considering stress and fatigue life

Cited by 7 publications

References 22 publications

Toward structure optimization for the mobile vehicle system based on multiconstraints

Toward structure optimization for the mobile vehicle system based on multiconstraints

Fatigue analysis and optimization design of key components of synthesizing equipment for artificial diamond based on a method of information exchange system

Lightweight Design of Special Axle Hub Based on ANSYS Consider Different Working Conditions for Low Carbon

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