from the conferences organized by TANGER Ltd.
The current automotive industry requires weight savings in the components used in the production of vehicles. At the same time, however, the demand for safety, high strength and fatigue life is increasing. This study aims to create a comprehensive methodology that will help designers and material engineers choose the appropriate technical solution and material for a highly stressed axle element. Specifically, the possibility of replacing the front axle weight produced from ductile iron with a high-strength aluminium alloy EN AW-7075 in T6 condition is addressed. As part of the solution concept, a 3D model was created and, using the finite element method (FEM), a simulation of the response of the mass to the load corresponding to traffic on the road was carried out. Furthermore, the technological procedure for testing automotive components using a multi-axis dynamic testing facility was established, where the DIC (Digital Image Correlation) method was used to evaluate load states and deformations. The basic limit states of vehicle operation, braking and cornering were tested. The work also deals with material factors that influence the choice of a suitable alloy, and verification of the degree of safety of the structural and material solution. The measurement results from both methods were compared with the contractual yield strength and fatigue strength. The results of FEM simulations and measurements using DIC positively verified the possibility of changing the material of the block, from ductile cast iron to EN AW-7075 strength aluminium alloy in T6 condition. The described methodology can therefore be used in the design, construction and implementation of car prototype chassis.
Keywords: Front axle beam, FEM, DIC, AW-7075 T6© This is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.