Ductile Fracture Prediction of Automotive Suspension Components

Paper #:
  • 2017-01-0318

Published:
  • 2017-03-28
Abstract:
Characterization of the plastic and ductile fracture behavior of a ferrous casting commonly used in the steering knuckle of an automotive suspension system is presented in this work. Ductile fracture testing for various coupon geometries was conducted to simulate wide ranges of stress states. Failure data for the higher stress triaxiality were obtained from tension tests conducted on thin flat specimens, wide flat specimens and axi-symmetric specimens with varying notch radii. While the data for lower triaxiality were generated from thin walled tube specimens subjected to combined axial-torsional loading and upsetting tests on cylindrical specimens. The failure envelopes for the material were developed utilizing the test data and FE simulations of the corresponding test specimens. Experiments provided the load-displacement response and the location of fracture initiation. FE simulations were conducted to calculate all the stress states, lode angle and strain components at the point of fracture initiation. Finally, comparisons of the predicted fracture load with data from physical test for various loading conditions with complex stress states are also presented.
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