Integrated predictions of the influence of mesh size, casting defects and SDAS on the fatigue life of aluminum alloy wheels

被引：0
|
作者：
Wang, Shihao [1 ,2 ]
Li, Zhongyao [1 ,2 ]
Ma, Xiaoying [3 ]
Wu, Xuelong [1 ,2 ]
Kong, Decai [3 ]
Qiao, Haibo [3 ]
Ci, Xiang [3 ]
Wang, Wenbo [3 ]
Lang, Yuling [3 ]
Xu, Shiwen [3 ]
Hou, Qinghuai [2 ,4 ]
Miao, Yisheng [2 ,4 ]
Chen, Yuanlu [2 ,4 ]
Wang, Junsheng [1 ,2 ,4 ]
机构：
[1] Beijing Inst Technol, Sch Mech Engn, Beijing 100081, Peoples R China
[2] Beijing Inst Technol, Adv Res Inst Multidisciplinary Sci, Beijing 100081, Peoples R China
[3] CIT Dicastal Co Ltd, 185 Longhai Rd,Econ & Technol Dev Zone, Qinhuangdao 066011, Hebei, Peoples R China
[4] Beijing Inst Technol, Sch Mat Sci & Engn, Beijing 100081, Peoples R China
来源：
JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T | 2025年 / 35卷
关键词：
Al casting; Fatigue life; Microstructure; Porosity; Mesh mapping; Grid convergence index (GCI); Secondary dendrite arm spacing (SDAS); MEAN STRESS; BEHAVIOR; OPTIMIZATION; SIMULATION; LIMIT;
D O I：
10.1016/j.jmrt.2025.02.091
中图分类号：
T [工业技术];
学科分类号：
08 ;
摘要：
In this study, a finite element-based fatigue prediction method that incorporates mesh size, casting defects, and secondary dendrite arm spacing (SDAS) is proposed. First, the grid convergence index (GCI) theory is employed to assess the mesh independence of fatigue life simulations for wheel radial fatigue, leading to the determination of an optimal mesh size of 5 mm. The aluminum alloy wheel casting process, including the assessment of casting defects and cooling rate distribution, is then simulated using a finite element model. An algorithm for transferring data from the process simulation model to the structural simulation model is developed. As a result, a radial fatigue model that accounts for the effects of porosity and SDAS in the wheel is established. The integrated fatigue model is used to predict the influence of mesh size, casting defects, and SDAS on wheel fatigue performance, enabling accurate prediction of radial fatigue life as a function of casting conditions. This work lays the foundation for process optimization aimed at improving the service life of aluminum wheel castings.
引用
收藏
页码：3956 / 3967
页数：12
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