Optimization and Fatigue Analysis of Front Axle Beam Truck Using FEM

Abstract

The vehicle industry is a vital part of the global economy. The front axle beam is one of the major parts of the vehicle suspension system. About 35 to 40 percent of the total vehicle weights are taken up by the front axle. The front axle is the most important part of the load-carrying in the vehicle. The additional weight on the vehicle parts might create excessive stress, resulting in irreversible deformation, failure, or fractures. The failure of the front axle is a serious concern to heavy vehicles and thus for human life. So it is necessary to analyze the axle beam’s skill to withstand typical service loading which develops stress in the beam failing. The main objective of this study is to develop the structural framework of design optimization and then apply topology optimization to enhance the strength and endurance requirements of the front axle beam. This is to analyze the front axle with different material such as structural steel, AISI 4340 steel normalized, AISI 4340 steel annealed, and AISI 4130 steel normalized, and also changing geometry of front axle and then apply topology optimization to enhance the strength and endurance requirements of the front axle. To fulfill strength and endurance requirements on the front axle beam, optimization is a useful tool to predict an optimal design in the early phases of the design process. In this thesis work, a completed design of an axle was constructed and topology shape optimization has been conducted on the front axle. So topology optimization is conducted on the front axle without sacrificing strength and durability. The topology optimization conducted as part of this thesis reduced the mass by 6.685% (mass reduction, of the front axle from 3990 kg to 3465.1 kg). The main part of the work done in this thesis includes parameterized FEA, design analysis, and topology optimization. The main contribution of this study is to investigate the possible methods of optimizing the strength and endurance required of the front axle.