Investigation of the similarity between physical tests and fatigue simulation of flange yoke made of C45 E material used in cardan shaftsUntersuchung der Vergleichbarkeit zwischen physikalischen Versuchen und Ermudungssimulation von in Gelenkwellen verwendeten Flanschmitnehmern aus dem Werkstoff C45 E

This study is focused on experimental and numerical estimation of the fatigue life of a flange yoke. The material's stress-life (fatigue) curve (S-N curve) for axial loading is constructed using specimens extracted from actual flange yokes. The torsional fatigue lives of components are determined by torsional fatigue tests of the complete cardan shafts. Simulation of the cardan shaft model including the flange yoke is carried out in Catia V5 R6 2016 software, which is then transferred to Altair Hyperworks 2017 software for the stress analyses. To predict the number of cycles to failure, the results are transferred into nCode 2018 DesignLife analysis module. An aim is to employ the stress-life curves as input in numerical calculations and finite element analyses to minimize the costly and time-consuming experimental work. The results show that physical testing and analysis results are in accordance when S-N curve of actual component material, as well as surface roughness factors measured from real component surface affecting fatigue life are incorporated into the analysis.

Automated summary

This study focuses on estimating the fatigue life of a flange yoke through experimental and numerical methods. By constructing the stress-life curve and conducting torsional fatigue tests, the researchers were able to predict the number of cycles to failure and minimize the need for costly and time-consuming experimental work. The results showed that incorporating the actual component's S-N curve and surface roughness factors into the analysis produced consistent results with physical testing.