A fatigue prediction method considering shrinkage cavity, secondary dendrite arm spacing (SDAS) and mean stress level is presented in the paper. Firstly, the casting process of an aluminum alloy wheel is simulated based on ProCAST software. And the data of SDAS and porosity of different parts are predicted based on the solidification process. Then the data mapping algorithm between tetrahedral mesh elements is developed to realize the unidirectional transformation of microcosmic data from a cast model to a static mechanical model. And the radial loading mechanical analysis model of a wheel containing microcosmic information is further established. According to the specific mechanical and fatigue parameters of each node, the fatigue life prediction model is established by Fesafe software. Based on the self-developed Transfer Couple Data (TCD) software, the integrated coupling method of the three software prediction models is realized, and the method is further used to realize a precise prediction of the radial fatigue life of a wheel considering effects of shrinkage cavity, SDAS and mean stress. Compared with the experimental results, after considering the microcosmic influence, the predicted position of the minimum life is unchanged, and the predicted life value is more accurate after considering the microcosmic influence. The proposed method lays a solid foundation of the optimization design and lightweight design of aluminum alloy wheels.

提出了一种考虑缩孔，二次枝晶臂间距（SDAS）和平均应力水平的疲劳预测方法。首先，基于ProCAST软件模拟了铝合金车轮的铸造过程。并根据凝固过程预测了不同部位的SDAS数据和孔隙率。然后，开发了四面体网格元素之间的数据映射算法，以实现微观数据从铸造模型到静态力学模型的单向转换。建立了包含微观信息的车轮径向载荷力学分析模型。根据每个节点的具体机械参数和疲劳参数，通过Fesafe软件建立疲劳寿命预测模型。基于自行开发的传输耦合数据（TCD）软件，实现了三种软件预测模型的集成耦合方法，并进一步考虑了收缩的影响，用于轮毂径向疲劳寿命的精确预测。腔，SDAS和平均应力。与实验结果相比，考虑微观影响后，最小寿命的预测位置不变，考虑微观影响后，预测寿命值更加准确。该方法为铝合金轮毂的优化设计和轻量化设计奠定了坚实的基础。并考虑收缩腔，SDAS和平均应力的影响，进一步实现车轮径向疲劳寿命的精确预测。与实验结果相比，考虑微观影响后，最小寿命的预测位置不变，考虑微观影响后，预测寿命值更加准确。该方法为铝合金轮毂的优化设计和轻量化设计奠定了坚实的基础。并考虑缩孔，SDAS和平均应力的影响，进一步实现了车轮径向疲劳寿命的精确预测。与实验结果相比，考虑微观影响后，最小寿命的预测位置不变，考虑微观影响后，预测寿命值更加准确。该方法为铝合金轮毂的优化设计和轻量化设计奠定了坚实的基础。