Fatigue Life of An Anti Roll Bar of A Passenger Vehicle
Fatigue Life of An Anti Roll Bar of A Passenger Vehicle
International Journal of Mechanical, Aerospace, Industrial, Mechatronic and Manufacturing Engineering Vol:6, No:2, 2012
Abstract—In the present paper, Fatigue life assessment of an That is, bent extended ends which are attached to each
anti-roll bar component of a passenger vehicle, is investigated by swing-arm via short vertical link-rods by means of rubber-
ANSYS 11 software. A stress analysis is also carried out by the bush joints. Thus the function of the antiroll bar is to relieve
finite element technique for the determination of highly stressed the main suspension springs of some of their load every time
regions on the bar. Anti-roll bar is a suspension element used at the the body rolls. An antiroll bar stiffens the suspension
front, rear, or at both ends of a car that reduces body roll by resisting
springing when the body rolls or one wheel goes over a bump
any unequal vertical motion between the pair of wheels to which it is
connected. As a first stage, fatigue damage models proposed by some
or dip in the road. The antiroll bar therefore permits softer
well-known references and the corresponding assumptions are suspension springing to be used when the vehicle is moving
discussed and some enhancements are proposed. Then, fracture straight ahead, as this responds far better than hard springing
analysis of an anti-roll bar of an automobile is carried out. The to small ripples or irregularities in the road, hence it improves
International Science Index, Mechanical and Mechatronics Engineering Vol:6, No:2, 2012 waset.org/Publication/14510
analysed type of the anti-roll bar is especially important as many the ride comfort of the passengers. In the extreme, some
cases are reported about the fracture after a 100,000 km of travel antiroll bars are tuned to take as much as 30–40% of the total
fatigue and fracture conditions. This paper demonstrates fatigue life vertical load imposed on the suspension when subjected to
of an anti-roll bar and then evaluated by experimental analytically severe body roll [2]. Fig. 1, shows the anti-roll bar in case of
results from other researcher.
the installation. The anti-roll bar picture analysed in this study
is given in Fig. 2.Recently many cases of fractured anti-roll
Keywords—Anti-roll bar, Fracture, Fatigue life, Random loading
bars after a 100,000 km of travel for a special passenger car
are reported. All of the bars are fractured at nearly the same
I. INTRODUCTION
location (Fig. 3). In this study, fracture analysis of this anti-
International Scholarly and Scientific Research & Innovation 6(2) 2012 407 scholar.waset.org/1999.8/14510
World Academy of Science, Engineering and Technology
International Journal of Mechanical, Aerospace, Industrial, Mechatronic and Manufacturing Engineering Vol:6, No:2, 2012
Fig. 2 The picture of the undamaged anti-roll bar analysed in this study
II.FATIGUE ASSESSMENT CRITERIA where J 2 and J 3 are the second and the third invariants of the
Stress-based multi-axial fatigue failure criteria have already deviatoric stress tensor, respectively, σ 1 , σ 2 , and σ 3 are the
been developed based on experimental observations. Some of
these criteria as well as some recently proposed criteria are principal stresses, and τ f and σ f are the fatigue failure
mentioned in the current section. stresses. In many applications, the stress state can be reduced
to a two-dimensional state including a normal stress and a
A. Von Mises and Tresca criteria
shear stress components only (e.g. for a component under
The analytical forms of these criteria are respectively [4]: combined bending and torsion). In these situations, (1), can be
Tresca criterion: rewritten as:
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International Journal of Mechanical, Aerospace, Industrial, Mechatronic and Manufacturing Engineering Vol:6, No:2, 2012
2 2 2 2
§ σa · § τa · § τ a · § σ n ,max ·
¨¨ ¸¸ + ¨¨ ¸¸ = 1 (4) ¨¨ ¸¸ + ¨¨ ¸¸ = 1 (9)
© σ R = −1 ¹ © τ R = −1 ¹ © τ R = −1 ¹ © σ R = − 1 ¹
where σ R =−1 and τ R=−1 are the fatigue strength values for the The weighted mean principal stress method is used to
determine the critical plane.
specified number of cycles to failure. In the present paper, the
following abbreviations are used, for simplicity: G.Ninic criterion
Ninic [12] has presented a criterion that modifies Gough’s
σ R ≡ (σ a ) R , τ R ≡ (τ a ) R (5) criterion as follows:
International Scholarly and Scientific Research & Innovation 6(2) 2012 409 scholar.waset.org/1999.8/14510
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International Journal of Mechanical, Aerospace, Industrial, Mechatronic and Manufacturing Engineering Vol:6, No:2, 2012
results of the pure bending (or pure tension) and pure torsion
fatigue experiments. Therefore, one may write: where (σ k )max R,f is the hydrostatic pressure value
corresponding to the fatigue failure at the specified ‘R’ value
§ τ max
2
· § σ n ,max ·
2
(if it is R-dependent). The function ψ may be determined
¨¨ ¸¸ + ¨¨ ¸¸ = 1 (15)
using experimental data. Therefore, both ‘f’ and ‘k’ parameters
©τ m +τ R ¹ ©σm +σ R ¹
may be considered as functions of ‘R’. Then, using the mean
stress correction, one has:
or
2 1/ 2
ª§ τ 2
· § σ n ,max · º τ eq = max (τ R + k σ n ) / 1 + k 2 τ R = − 1 / τ R (19)
σ eq = «¨¨ max ¸¸ + ¨¨ ¸¸ » σ R =−1 (16) θ ,ϕ ,ψ ,t
«¬© τ m + τ R ¹ ©σ m +σ R ¹ »¼
On the other hand, if the ‘f’ parameter is considered as a
where σ eq is the equivalent fully reversed normal stress. The function that is independent of ‘R’, then, from the uni-axial
above equations are valid for proportional loadings. For non- cyclic loading, one has:
proportional loadings, σ n ,max and τ max do not occur
σ R2 + k 2 (σ m + σ R ) 2 + k .( σ m + σ R ) = 2 1 + k 2 τ R
simultaneously. Generally, for non-proportional loading, a (20)
criterion whose expressions change with time is more suitable. σ k + 1+ k 2
R =0 =
Therefore, the corresponding critical plane may be found by a σ R = −1 2 k + 1 + 4 k 2
time marching method. Thus, equations such as (3), (4), (9),
(10) and (12) that contain stationary parameters, may not seem This equation can be used to determine the ‘k’ parameter.
to be useful for a life assessment under a non-proportional
random loading. Furthermore, (3), (4) and (11) suffer from the L. McDiarmid criterion
fact that their results show no difference between the positive Using the same limit cases that are mentioned in the
and the negative σ m values. It is an evident that compressive previous section, one has:
normal stresses, in contrast to the tensive ones, tend to close
the crack enclosure and subsequently, enhance the fatigue f = (τ a ) AorB = τ R
(21)
strength. (σ a ) R , f = 2σ u
J. Sines criterion
Generally, the second identity does not hold. If we use the
Since for non-proportional loadings, Δ(σ 1 − σ 2 ) ≠ function ψ that is defined in (19), we have:
Δσ 1 − Δ σ 2 ) difficulties arise when calculating (J 2 )a . However, τ eq = [τ a + (σ n ) max(t ) /ψ ].τ R =−1 / τ R (22)
in the present research, in contrast to the other references,
Δ J 2 is not computed substituting the principal stresses by This equation must be calculated on a plane with maximum
their increments in the J 2 expression. Δ J 2 and ( J 2 )a shear stress. Using the limit uni-axial cyclic tension case
where τ a = σ R / 2 and σ n ,max = (σ m + σ R ) / 2 one has:
expressions are derived by a time marching procedure in the
current paper. Besides, according to the uniaxial fatigue
experiments data, it is easily verified that [18]: 2τ R − σ R
k= (23)
σm +σR
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World Academy of Science, Engineering and Technology
International Journal of Mechanical, Aerospace, Industrial, Mechatronic and Manufacturing Engineering Vol:6, No:2, 2012
1+ k σ σ − σ R =0 (24)
= R =0 k = R =−1 Solving the model for the specified loads time histories
1 + 2k σ R = −1 2σ R =0 − σ R =−1 and boundary conditions to extract the stress
components time historis.
M. Carpinteri–Spagnoli theory
Mean stress effect is not included in (9). It is an evidence
Choosing regions of the component that are more
that when the mean shear stress value of a component reaches likely to fail in fatigue.
the ultimate shear stress value, the component will fail with
(τ a = 0, σ n ,max(t ) = 0) . Therefore, it seems that (15) is more
Determination of the equivalent stress time history
general than (9). (including application of rain flow method on the time
histories of the stress components).
N.Ninic equation
International Science Index, Mechanical and Mechatronics Engineering Vol:6, No:2, 2012 waset.org/Publication/14510
International Scholarly and Scientific Research & Innovation 6(2) 2012 411 scholar.waset.org/1999.8/14510
World Academy of Science, Engineering and Technology
International Journal of Mechanical, Aerospace, Industrial, Mechatronic and Manufacturing Engineering Vol:6, No:2, 2012
of the analysis is to determine the highly stressed region of the σ yp . This location is loaded by bending and torsion because
cross-section. This determination allows us to assign the of the geometry and boundary conditions. The highest stress is
beginning point of the fracture. obtained at the inner point of this curved location. The fatigue
The finite element mesh is generated with SOLID 95 crack is initiated and propagated from this location.
elements from the element library. This element is a
tetrahedron with 20 nodes and 30 degrees of freedom and very
sensitive for this type of three-dimensional problems [16, 17].
Smart meshing technique is applied for the mesh generation to
allow the program to determine the most appropriate meshing.
As a result, the element and node numbers of the solution
domain are 18266 and 30514, respectively.
International Science Index, Mechanical and Mechatronics Engineering Vol:6, No:2, 2012 waset.org/Publication/14510
has been used the experimental data from reference [18] for
40 validation of FEM results. The FEM model is validated by
30
comparing the static stiffness results obtained from the FEM
analysis with the experimental ones. Number of cycles to
20
failure calculated using FEM model via software ANSYS 11
10
is 55,040 cycles and Number of cycles to failure is calculated
using various theories. Results are given in Table I.
0
To see the mean stress effects, another input is also applied
-10 and also number of cycles to failure calculated using FEM
model via software ANSYS 11 is 140,870 cycles. As before,
-20
0 5 10 15 20 25 the corresponding results are also given in Table I.
Time (seconds) For the special cases studied, according to results shown in
Table I, modified Sines criterion offers the lowest life values.
Fig. 6 The second block signal applied on the anti-roll bar component
For fully reversed displacement inputs, the more accurate
[15]
criteria may be ordered based on the accuracy level as: the
As a result of the study, the maximum stresses obtained at
general criterion, Gouph and Pollard criterion, Ninic criterion
the third bent location of the bar. To insure that no yielding
and the modified von Mises theory, respectively. Since more
occurs during loading, so that the fatigue failure occurs in the
stress components may be considered in the general criterion,
HCF regime, the effective (Von Mises) stresses of the
lower life is predicted by the general criterion in comparison
component are determined based on the greatest stress
with Gough–Pollard or Ninic criteria. Significant
amplitude of the time history illustrated in Fig. 7. The
discrepancies are noticeable in the results of the second type
corresponding results are illustrated in Fig. 7 in Pa. As it may
input. Results of von Mises theory are also computed. They
be noticed from Fig. 6, the maximum value of the effective
are omitted because they were unjustifiably lower than the
stress is 583 MPa which is greater than σ R = −1 and less than
other results.
International Scholarly and Scientific Research & Innovation 6(2) 2012 412 scholar.waset.org/1999.8/14510
World Academy of Science, Engineering and Technology
International Journal of Mechanical, Aerospace, Industrial, Mechatronic and Manufacturing Engineering Vol:6, No:2, 2012
For the second type of loading, the more accurate criteria [11] A. Spagnoli, “A new high-cycle fatigue criterion applied to out-ofphase
biaxial stress state,” Int J Mech Sci, vol. 43, pp. 2581–95, 2001.
may be ordered based on the accuracy level as: the general [12] HJ. Gough, HV. Pollard, “The strength of metals under combined
criterion, the modified von Mises theory, and the modified alternating stresses,” Proc Inst Mech Eng, vol. 131, pp. 1–103, 1935.
Findley criterion, respectively. Remarkable enhancements are [13] Y. Liu, S. Mahadevan, “A unified multiaxial fatigue damage model for
noticed due to using the modifications proposed in the present isotropic and anisotropic materials,” Int J Fatigue,vol. 29, pp. 347–59,
2007.
paper. Furthermore, there exist good agreements between the [14] DH. Wright, “Testing automotive materials and components,” McGraw-
results of the general criterion and the experimental results. Hill Publishing Co., 1993.
[15] M. Shariyat, “A fatigue model developed by modification of Gough’s
theory, for andom non-proportional loading conditions and three-
V.CONCLUSIONS dimensional stress fields,” Int J Fatigue, vol. 30, pp. 1248–1258, 2008.
In the present paper, as a first stage, some modifications are [16] J. Schijve, “Fatigue of structures and materials,” Secaucus, (NJ, USA):
Kluwer Academic Publishers, 2001.
proposed to some existing fatigue failure models. Many hints [17] ANSYS 5.4 versions users manual.
that may be considered to develop general fatigue failure [18] M. Shariyat, A. Ganjidoust, “Fatigue failure and damage analysis of an
models for three-dimensional stress fields with random, non- anti-roll bar under random fatigue tests,” Journal of Solid Mechanics,
pp. 3–20, 2010.
proportional loadings are mentioned. Then, fatigue life of an
anti-roll bar component of a passenger vehicle, is investigated
International Science Index, Mechanical and Mechatronics Engineering Vol:6, No:2, 2012 waset.org/Publication/14510
by numerical method and finally comparison is made among Javad Marzbanrad is an associate professor in
Automotive Engineering at Iran University of Science
the results of the FEM analysis, results of the existing theories, and Technology. He was born in 1964 in Tehran, Iran.
results of the modified versions of the theories, as well as the He got his Ph.D’s Degree in 2001 from Tarbiat
experimental results. The presented results confirm the Modarres University. He was in the Clarkson
University, NY, U.S. in 2000-01 as visiting scholar.
accuracy of numerical fatigue analysis. His research interests are Automotive, Control and
Vibration and Solid Mechanics. Now, he is the faculty
TABLE I
of School of Automotive Engineering in Iran
COMPARISONS AMONG THE RESULTS OF THE EXISTING THEORIES, RESULTS OF
University of Science and Technology. He has more than 150 published
THE MODIFIED OR PROPOSED CRITERIA, AND THE EXPERIMENTAL RESULTS
papers in the conferences and journals. He also published three books in
Result Title Fully reversed input Input shown in Fig.5 mechanical software fields. He has also registered six inventions in Iran.
This study (ANSYS) 55,040 140,870 Aref Yadollahi was born in 1984 in Semnan, Iran. He
Experimental [18] 49,500 116,820 got his MSc’s Degree in 2010 from Iran University of
Gough-Pollard 70,301 328,371 Science and Technology. His research interests are
Modified sines 23,275 58,901 Automotive, NVH and Solid Mechanics. Now, he is the
Fidley 90,146 280,892 tutor of Automotive Department in the Islamic Azad
McDiarmid 91,713 296,172 University, Semnan Branch. He has more than 10
Carpinteri-Spagnoli 76,799 276,855 published papers in the conferences and journals. He
Ninic 70,301 213,673 also published one book in mechanical software field.
Modified Fidley 82,614 196,563
Modified McDiarmid 78,346 226,389
Modified Von Mises 81,713 186,407
The general criterion 67,168 162,623
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