Multi-body simulation with notch stress analysis of an axle assembly

The optimization of mining vehicle rear axle weld joints is a complex procedure. The designs for low-cycle fatigue with peak loads were analyzed using computational models and rig testing. On-road evaluation of high-cycle fatigue was performed with the entire vehicle. The iterative analysis is used in design optimization to minimize design cycle time. In sophisticated fatigue calculations with all affecting factors, FEM is utilized. In fatigue failures using road load data, the present deterministic method yields up to 80% correlations. Some critical failure spots were most likely missed owing to operational variations caused by the randomness and multiaxiality of load transfer in link mechanisms with non-linear elements. The fabricated rear axle housing joints are optimized by comparing damage state estimates using stochastic type and multiaxial equivalent loads obtained using Multibody Simulation. The damage state analysis as MBS input stimulus in FE weld models and bolted designs were compared.