Abstract Cornering fatigue test of an automotive wheel is one of the essential tests to ensure the structural integrity of a wheel disc. Forming operation of wheel disc introduces forming history such as thickness reduction, pre-strain, and mean residual stresses. In this work, a methodology is proposed to consider the factors affecting the cornering fatigue performance of DP600 automotive wheel disc. The cyclic elastic-plastic Finite Element (FE) simulations are performed using the Chaboche kinematic hardening model. Local stress-strain states of critical element evaluated from FE simulations and fatigue parameters obtained from symmetric strain and stress controlled tests are coupled to predict the cornering fatigue life. Maximum equivalent stress and stress triaxiality at the cup radius region indicates a possible site for fatigue crack initiation. The incorporation of thickness variation and pre-strain effect is found to be the two most significant parameters for the accurate estimation of cornering fatigue life and failure location of wheel disc.

中文翻译：

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厚度变化和预应变对DP600钢轮盘过弯疲劳寿命预测的影响

摘要 汽车车轮过弯疲劳试验是保证轮盘结构完整性的重要试验之一。轮盘的成形操作引入了成形历史，例如厚度减小、预应变和平均残余应力。在这项工作中，提出了一种方法来考虑影响 DP600 汽车轮盘过弯疲劳性能的因素。循环弹塑性有限元 (FE) 模拟使用 Chaboche 运动硬化模型进行。从有限元模拟评估的关键元素的局部应力应变状态与从对称应变和应力控制测试中获得的疲劳参数相结合，以预测转弯疲劳寿命。杯形半径区域的最大等效应力和应力三轴性表明疲劳裂纹萌生的可能位置。厚度变化和预应变效应的结合被发现是准确估计转弯疲劳寿命和轮盘失效位置的两个最重要的参数。