Influence of Thermal Treatment and Design Parameters on the Fatigue Life of Automotive Control Arm Fabricated from A357 Semi-solid Alloy

Attia, Mohamed; Ragab, Kh. A.; Bouazara, Mohamed; Chen, X. Grant

doi:10.1007/978-3-030-36408-3_42

Cited by 1 publication

(2 citation statements)

References 12 publications

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“…During operation, they are subjected to several mechanical loads in static and dynamic situations, which create a high risk of initiating a crack or complete failure. In automotive approval, this part has been subjected to several research and validation purposes in different areas such as statics [ 1 , 2 , 3 , 4 ], fatigue [ 3 , 4 , 5 ], dynamics [ 6 ], vibration [ 7 ], and thermal scenarios [ 5 ]. Finally, after these partial validations, the lower control arm will go through another final validation with vehicle synthesis tests for crash tests.…”

Section: Introductionmentioning

confidence: 99%

“…They conducted the study in two parts: a numerical part and an experimental part. In this sense, Mohamed Attia et al [5] have carried out a fatigue study of the lower control arm in aluminum material A357 in a dynamic case (Figure 2), and they pushed further the study of heat treatment in order to attain the mechanical and thermal properties of the lower control arm in aluminum material compared to steel materials. During the manufacturing process, some parts may develop defects that are not detected during quality control.…”

Section: Introductionmentioning

confidence: 99%

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Predicting Stress Intensity Factor for Aluminum 6062 T6 Material in L-Shaped Lower Control Arm (LCA) Design Using Extended Finite Element Analysis

El Fakkoussi,

Vlase,

Marin

et al. 2023

Materials

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The aim of this study is to solve a practical problem encountered in the automotive industry, especially the failure of a cracked lower control arm made of al 6062 T6 material during static and crash physical tests, and to characterize the behavior of cracked parts made of aluminum materials using the fracture mechanics parameters. As a first step, we carried out a numerical study and simulation using Abaqus/CAE 2020 software and the finite element method to determine the stress concentration and load limit capacity for different car weight cases. The von Mises stress variation shows crack initiation and propagation to be in the area of the lower control arm’s attachment to the vehicle platform, where stress is concentrated. These numerical results are consistent with the experimental test results found by automotive manufacturers. Also, we find that the mechanical load that can support this part is below 4900 N for good performance. In the second step, we use the results of the first section to simulate the failure of a lower control arm with a crack defect. This paper investigates the stress intensity factor KI in mode I for different lengths (L) and depths (a) of the crack in the lower control arm using the extended finite element method (XFEM) under Abaqus/CAE. For crack failure initiation and progression, we relied on the traction separation law, specifically the maximum principal stress (MAXPS) criterion. The KI factor was evaluated for the materials steel and Al 6062 T6. The results obtained from the variation of the KI coefficient as a function of crack depth (a) and the thickness (t) show that the crack remains stable even when a depth ratio (a/t = 0.8) is reached for the steel material. However, the crack in the Aluminum 6062 T6 material becomes unstable at depth (a/t = 0.6), with a high risk of total failure of the lower control arm.

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