Casting and spinning aluminum alloy wheel fatigue properties and life prediction study

Abstract

To accurately predict the fatigue life of cast aluminum alloy wheels, based on the results of finite element calculation and simulation, this work selected the rim area, inner flange and spoke areas to conduct systematic tensile and high‐cycle fatigue tests. The results show that the tensile properties of A356‐T6 cast aluminum alloy wheels are similar in various areas, but the fatigue properties are significantly different. Plastic deformation can improve the fatigue strength of the aluminum alloy, but the fatigue properties are also affected by deformation uniformity and other factors. Based on the difference of mechanical properties in different areas, this study also selected the characteristic loading spectrum to predict the fatigue life of wheels. A linear and a nonlinear damage accumulation were employed. The above methods are not only applicable to the wheel, but also provides a new idea for the life prediction of key parts in the engineering field.

Numerical simulation of spinning forming of A356 aluminum alloy hub using dual spinning rollers

“…The production and preparation processes of aluminum alloy hubs mainly include the casting method, forging method, and casting-spinning forming method. Among them, the spinning formed hubs have become an important development direction for hub production due to their advantages such as lightweight and good mechanical properties [2] . However, the spinning production of wheel hubs is a large plastic deformation process of metal, which is prone to defects such as wrinkling, uneven wall thickness, and unqualified dimensions, resulting in material waste and reducing the production efficiency of enterprises.…”

Fatigue Behaviors and Dislocation Evolution of Copper and Aluminum Alloy

“…For the widely used structural materials such as copper alloy, aluminum alloy, nickel base superalloy, and so on, the existence of a large number of mechanisms affects fatigue fracture, so it is difficult to carry out research on fatigue properties of FCC metals as typical materials. [14][15][16] Meanwhile, single crystal FCC materials lack grain boundary effects and have poor processability, making the results of corresponding research difficult to guide industrial production and application. In summary, polycrystalline deformable metals with a wide range of application foundations are very suitable for conducting research on the fatigue fracture behavior of FCC metals.This work selects copper and aluminum alloys with high value of engineering application, represented by 1060-O (incomplete annealed 1060 aluminum alloy), 1060-H (work hardened 1060 aluminum alloy), and Cu (cold deformation), to conduct study on the high cycle fatigue (HCF) performance at room temperature and high temperature (115 °C).…”

“…For the widely used structural materials such as copper alloy, aluminum alloy, nickel base superalloy, and so on, the existence of a large number of mechanisms affects fatigue fracture, so it is difficult to carry out research on fatigue properties of FCC metals as typical materials. [14][15][16] Meanwhile, single crystal FCC materials lack grain boundary effects and have poor processability, making the results of corresponding research difficult to guide industrial production and application. In summary, polycrystalline deformable metals with a wide range of application foundations are very suitable for conducting research on the fatigue fracture behavior of FCC metals.…”