International Journal of Advanced Research in Engineering and TechnologyRESEARCH (IJARET), ISSN 0976 INTERNATIONAL JOURNAL OF ADVANCED IN 6480(Print), ISSN

N 0976 6499(Online) Volume 4, Issue 2, March April (2013), IAEME ENGINEERING AND TECHNOLOGY (IJARET)

ISSN 0976 - 6480 (Print) ISSN 0976 - 6499 (Online) Volume 4, Issue 2 March April 2013, pp. 119-124 IAEME: www.iaeme.com/ijaret.asp Journal Impact Factor (2013): 5.8376 (Calculated by GISI) www.jifactor.com

IJARET
IAEME

COMPARATIVE STUDY OF SAE 1045 (CARBON STEEL) AND ALUMINIUM ALLOY 7075-T6 FOR LOWER SUSPENSION ARM OF A SEDAN CAR
Prof. Pinank A. Patel1 1 Department of Mechanical Engineering, Marwadi Education Foundations Group of Institutions-Rajkot, India, Vivek G. Patel2 Department of Mechanical Engineering, Marwadi Education Foundations Group of Institutions-Rajkot, India,
2 3

Dr. Shashikant S. Khandare3 Principal B.D. Collage of Engineering-Wardha,

ABSTRACT Automobile parts are subjected to variable amplitude loads; fatigue characteristics vary with material and loading conditions. This research focuses on the finite element based fatigue life prediction of lower suspension arm subjected to numerous loads. Objectives of this analysis are to predict fatigue life of the lower suspension arm using Strain-life approach and to discover suitable material for the suspension arm. The CAD model of lower suspension arm is developed using ProE (Wildfire4.0); later transferred to Ansys 12.1, where finite element analysis for fatigue life analysis was performed employing the Strain-life approach subjected to variable amplitude loading. While performing fatigue analysis, two types of non-uniform variable amplitude loads are considered including zero mean loading (SAEBKT) and positive mean loading (SAETRN). We employed Morrow and SWT Method, wherein tetrahedron mesh is applied to the model for fatigue analysis. Keywords: Fatigue Life, Strain Life Approach, Aluminum Alloy, Non uniformly Varying Load (SAEBKT, SAETRANS)

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International Journal of Advanced Research in Engineering and Technology (IJARET), ISSN 0976 6480(Print), ISSN 0976 6499(Online) Volume 4, Issue 2, March April (2013), IAEME

I.

INTRODUCTION

Recent technological research and efforts have focused on new automobile material forms. At present, in automotive industry it is very crucial task to produce lighter; cheaper and more efficient parts can sustain high loads. Every automotive suspension is meant for two aims; vehicle control and passenger comfort. A good car suspension system should have satisfactory road holding ability, while providing comfort during riding over bumps and pits on the road. For the prediction of fatigue life stress and strain life approach can be applied, due to presence of stress concentrated area stress life cant give accurate results. For here we employed strain life approach for the prediction of fatigue life of lower suspension arm. II. STRAIN LIFE APPROACH

Strain life method is employed where plastic deformation occurs at critical regions (like notches). In this method plastic strain or deformation is directly measured and quantified because Stress life approach h fails to account for plastic strain. Even when the component is under heavy loading conditions, it is necessary to have a plastic deformation at stress concentration zone where strain life approach is superior to stress life approach. The local Strain Life fe approach has gained acceptance as a useful method of evaluating fatigue life of a component. The Strain-Life Curve can be formed by summing up the elastic and plastic strains.

Total Strain, t = e + p 2 =

' f

(2Nf) + 'f (2Nf)

E

The effect of the elastic and plastic components on the strain-life strain life curve is shown in Figure 1.

Figure 1 : Strain Life Curve

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International Journal of Advanced Research in Engineering and Technology (IJARET), ISSN 0976 6480(Print), ISSN 0976 6499(Online) Volume 4, Issue 2, March April (2013), IAEME

'f - o Morrows s Strain Life Equation: a =

(2Nf) + 'f (2Nf)

E

Smith-Watson-Topper (SWT):

max a E = ('f ) (2Nf) + 'f ' E (2Nf)

III.

CAD MODEL, BOUNDARY CONDITION AND MESHED MODEL

Figure shows CAD model of lower suspension arm and its bounding box dimensions are mentioned in table.

Direction X Y Z Figure 2 : Cad Model

Length 436.03 363.52 65.00

Unit mm Mm Mm

Figure 3 shows the meshed model of lower suspension arm with 2.0 mm of mesh size and 10node Tetrahedron element (TET10) were considered for the analysis. Figure 3 shows boundary condition applied to the Lower suspension arm.

Figure 3 : Meshed Model and Boundary Condition IV. MATERIAL PROPERTIES

Fatigue behavior of any material is highly dependent on its tensile strength; higher the tensile strength, material will have high fatigue life. The mechanical properties of C45 & AL 7075-T6 T6 (Aluminum alloy) are shown in Table
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International Journal of Advanced Research in Engineering and Technology (IJARET), ISSN 0976 6480(Print), ISSN 0976 6499(Online) Volume 4, Issue 2, March April (2013), IAEME

Table 1: Material Properties Properties Strain-Life Parameters Strength Coefficient Strength Exponent Ductility Coefficient Ductility Exponent Cyclic Strength Coefficient Cyclic Strain Hardening Exponent V. LOADING CONDITION Unit Pa C45 1099000000 -0.11 0.52 -0.54 1402000000 0.201 AL 7075-T6 876323996 -0.0751 0.4664 -0.7779 943203168 0.0966

Pa

The standard ultimate loading cases what we considered are as shown in Table 2. For prediction of fatigue life of lower suspension arm we considered two non-constant varying load SAEBKT (Bracket History) and SAETRANS (Transmission History) as shown in Figure 4&5. Table 2: Loading Condition Conditions X Pothole brake limit load 5688.2 Oblique kerb limit load -9579.7 Lateral kerb strike limit load 549.7

A B C

Y 60.4 238.3 845.9

Z 4801.2 2382.1 12218.3

Figure 4: Sae Bracket History

Figure 5: Sae Transmission History VI. RESULTS

From the following results it is being clear that fatigue life of lower suspension arm is considerably increased by employing AL7075-T6 aluminum alloy as a lower suspension arm. Lateral kerb limit is the highest loading condition.

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International Journal of Advanced Research in Engineering and Technology (IJARET), ISSN 0976 6480(Print), ISSN 0976 6499(Online) Volume 4, Issue 2, March April (2013), IAEME

Figure 6: Lateral kerb strike limit load / Bracket / AL7075-T6

Figure 7: Lateral Kerb Strike Limit Load / Bracket / C45

Figure 8: Lateral kerb strike limit load /Transmission/ AL7075-T6

Figure 9: Lateral kerb strike limit load/Transmission/ C45

Strain Life Load Cases SAEBKT Pothole brake limit load Oblique kerb limit 2 load Lateral kerb strike 3 limit load 1 32232 923866 2268 C45 SAETRANS 124833 3404196 1058 AL 7075 T6 Bracket 111763 175206502 805 Transmission 123848 444289956 1197

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International Journal of Advanced Research in Engineering and Technology (IJARET), ISSN 0976 6480(Print), ISSN 0976 6499(Online) Volume 4, Issue 2, March April (2013), IAEME

CONCLUSION From the analysis of lower suspension arm it is concluded that if Al alloy (Al 7075T6) will give comparative higher fatigue life then C45. Hence, weight of the component made up from Al Alloy (Al 7075-T6) is subsequently reduced (Approx 60%). REFERENCES
[1] Sigmund Kyrre s, "Study of fatigue crack initiation in rough surfaces using the finite element method and measured surface topography," Norwegian University of Science and Technology, Trondheim, Norway, 2005. [2] N.A. AL-ASADY, A. K. ARIFFIN, M.M. RAHMAN, AND Z. M. NOPIAH S. ABDULLAH, "FEA Based Fatigue Life Assessment of an Automobile Lower," International Conference on APPLIED and THEORETICAL MECHANICS, vol. 4th, 2008 [3] K. Kadirgama, M. M. Noor, M. R. M. Rejab, S. A. Kesulai M. M. Rahman, "Fatigue Life Prediction of Lower Suspension Arm Using Strain-Life Approach," European Journal of Scientific Research, vol. 30, no. 3, pp. 437-450, 2009. [4] M.M. Rahman, K. Kadirgama, M.M. Noor and Rosli A. Bakar Z. Husin, "Prediction of fatigue life on lower suspension arm subjected to variable amplitude loading," in National Conference in Mechanical Engineering Research and Postgraduate Studies, Pahang, Malaysia, 2010, pp. 100-116. [5] S. Abdullah, A. K. Ariffin, S. M. Beden, and M. M. Rahman N. A. Al-Asady, "Fea based durability using strain-life models for different medium carbon steel as fabrication materials for an automotive component," International Journal of Mechanical and Materials Engineering (IJMME), vol. 4, no. 2, pp. 141-146, 2009. [6] Rahman M. M, and Omar R.M Hemin M. M, "Novel Design of Lower Arm Vehicle Using Finite Element Analysis and Statistical Method," Journal of Advanced Science and Engineering Research, vol. 2, pp. 27-39, March 2012. [7] N.A.Al-Asady, A.K. Arrifin, M.M. Rahman S. Abdullah, "A Review on Finite Element Analysis Approaches in Durability Assessment of Automotive Components," Journal of Applied Sciences, no. 8, 2008. [8] MOHD KHAIRIL AZIRUL BIN KHAIROLAZAR, "Robust design of lower arm suspension using stochastic," university malaysia pahang, MALAYSIA, 2009. [9] Bernd Heiing & Metin Ersoy, Chassis Handbook, ed., Bernd Heiing and Metin Ersoy., Ed. Berlin, Germany: MercedesDruck, 2011. [10] ArkanJawdat Abassa , DhaferSadeq Al-Fatal, Experimental And Theoretical Study Of The Influence Of The Addition Of Alumina Powder To 7020 Aluminum Alloy Foam On The Mechanical Behavior Under Impact Loading International Journal of Mechanical Engineering & Technology (IJMET) Volume 3 Issue 3 (September - December 2012) pp. 412 - 428, ISSN PRINT : 0976 6340, ISSN ONLINE : 0976 - 6359. Published By IAEME. [11] I.M.Jamadar, S.M.Patil, S.S.Chavan, G.B.Pawar and G.N.Rakate, Thickness Optimization of Inclined Pressure Vessel Using Non Linear Finite Element Analysis Using Design by Analysis Approach International Journal of Mechanical Engineering & Technology (IJMET) Volume 3 Issue 3 (September - December 2012) pp. 682 - 689 ISSN PRINT: 0976 6340, ISSN ONLINE: 0976 - 6359. Published By IAEME. [12] U. D. Gulhane, M.P.Bhagwat, M.S.Chavan, S.A.Dhatkar And S.U.Mayekar, Investigating The Effect Of Machining Parameters On Surface Roughness Of 6061 Aluminium Alloy In End Milling International Journal of Mechanical Engineering & Technology (IJMET) Volume 4 Issue 2 (March - April 2013) pp. 134 140, ISSN PRINT: 0976 6340, ISSN ONLINE: 0976 6359. Published By IAEME.
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