Fatigue analysis and weight reduction studies in rear axle design using different materials

Karaçor B., Hükümdar Ö., Ekşi Ü., Divanoğlu A., Özcanlı M.

7th International Mediterranean Science and Engineering Congress(IMSEC 2022), Antalya, Turkey, 24 - 26 October 2022, pp.255-262

  • Publication Type: Conference Paper / Full Text
  • City: Antalya
  • Country: Turkey
  • Page Numbers: pp.255-262
  • Çukurova University Affiliated: Yes


The rear axle, which is one of the most important structures of a vehicle, has the main function of directing the movement from the differential to the wheels. The aim of this study is to design a rear axle using ultra high strength material, and to analyse this design using the finite element method (FEM) by comparing it with the currently used structural steel rear axle. Structural steel and AISI 4340 ultra-high-strength steel were preferred as the rear axle design material. First, the rear axle was designed using the CATIA (Computer Aided Three-Dimensional Interactive Application) then analyses were performed using the finite element method (FEM) with ANSYS software. The results of the study are presented as a comparison of two different materials in terms of weight, deformation and stress values, life (cycle), damage, equivalent alternative stress and biaxiality indication distribution. The analysis outcomes indicate that the use of AISI 4340 material would result in a weight reduction of 9.16% and 1.56 times increase in the fatigue cycle for the rear axle compared to structural steel design.