Effects of Geometry Design Parameters on the Fatigue Failure of a Drive Axle Housing using Finite Element Analysis

The current paper investigates the effects of geometric design parameters on the fatigue failure of the drive axle housing using the Finite Element Method (FEM). The study examines the effects of various factors on the fatigue life of the drive axle housing, such as axle housing wall thickness, housing cross-sectional rounding radius, and rounding radius of the central part of the housing. Based on the known material properties and dynamic loads, a CAD/FEM model of the drive axle housing was developed, and a structural analysis was carried out. Based on the results of the structural analysis, critical places on the housing were determined, and fatigue analysis and lifetime prediction were performed. Through a series of simulations, the study reveals that increasing housing wall thickness can significantly improve fatigue performance. Similarly, increasing the rounding radius at the housing cross-section, as well as the rounding radius at the central part of the housing can also lead to improved fatigue performance. However, the effect of increasing the value of these two radii is not as significant as the effect of the wall thickness. These findings give useful information regarding the design and manufacture of drive axle housings for vehicles, intending to reduce the likelihood of fatigue failure.