Technical Paper
A Computational Methodology for Multi-Objective Fatigue Life Optimization of Welded Brake Flange on Full Beam Axles
2018-04-03
2018-01-1019
Weld failure of a brake flange can put a driver’s life at risk. Two critical loading situations-torsional loading and vertical beaming loading-can result in brake flange failure. Two corresponding laboratory tests have been performed to ensure that the brake flanges pass the minimum standard requirement. The first is a brake reaction test, which is conducted in a situation that replicates the sudden braking operation of a vehicle. For this test, length, size, and penetration depth of the weld are critical parameters for determining the ability to prevent braking load failure. Among these factors, the length is the most crucial. The second test is a vertical beaming test, which is done in a condition that mimics the situation where a vehicle encounters a pot hole. Contrary to the previous test, an increased weld length can be detrimental in this case when the weld is moved to a higher stress location.