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, P. F. Li, D. M. Maijer, T. C. Lindley, "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