Integrated CAE methodologies, devoted to the numerical analysis of cast aluminum suspension components with regard to fatigue and impact loads, has been presented. Assuming as a case study the rear arm of a multi-link suspension, manufactured in A356-T6 aluminum alloy by means of low pressure die casting, the methodologies have been successfully applied and allowed to predict accurately the fatigue life, the critical load (maximum bearable load) and the post-buckling behavior of the component. For a correct end efficient use of the methodologies, FE discretisation techniques of 3D-solid suspension components have been reviewed and discussed, and some general guidelines have been obtained. With regard to durability analysis, FE modeling using hexahedral elements has proven to be the most robust and appropriate, especially when both local stresses and relative stress gradients should be calculated for a reliable fatigue life prediction. Moreover, the noticeable influence of relative stress gradients on the fatigue behavior has been pointed out; consequently, a specific damage calculation procedure accounting for this crucial aspect has been developed and applied. With regard to analysis under impact loads, the mixed FE modeling technique results to be a useful approach for numerical evaluation of 3D-solid components such as suspension arms. On the other hand, depending on the component dimensions, the numerical methodology based on perturbation of the perfect model with the lowest buckling modes, can be successfully used during virtual prototyping of suspension components in order to change the critical load. The validated methodologies are applicable for the virtual analysis and prototyping of new cast aluminum suspension components, allowing one to obtain thereby noticeable advantages in terms of product performance improvement as well as time and costs reduction.
CAE methodologies for virtual prototyping of cast aluminium suspension components
CAE-Verfahren für die virtuelle Prototypentwicklung von Aufhängungsbauelementen aus Aluminiumgußlegierung
2002
10 Seiten, 27 Bilder, 3 Tabellen, 5 Quellen
Conference paper
English
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