A Validated Through Process Model to Predict the Fatigue Life of a Cast A356 Automotive Wheel
Models describing the critical steps in the manufacturing process of aluminum alloy wheels were integrated with a model of in-service loading to predict component fatigue performance. A multiscale solidification model was coupled with models of the subsequent heat treatment and machining to predict the residual stress distribution in a finished wheel. A second multiscale model was incorporated into a service model to relate the pore size and local stress state to fatigue performance. The predictions resulting from this through process modeling approach have been validated by comparisons with a series of measurements: 1) thermocouple measurements during casting; 2) characterization of pore size and distribution using X-ray microtomography and optical metallography; 3) residual strain measurements on finished wheels; 4) in-service strain measurements during a rotating bend test; and 5) in-service fatigue performance during rotating bend tests.
W.J. Poole, M.A. Wells and D.J. Lloyd
P. D. Lee et al., "A Validated Through Process Model to Predict the Fatigue Life of a Cast A356 Automotive Wheel", Materials Science Forum, Vols. 519-521, pp. 1777-1782, 2006