I am working on a project regarding the testing of aluminium steering knuckles and suspension links. I would like to know how I can simulate or calculate realistic load conditions for FEA and bench testing to test its strength and durability.
Can I get any road profile data and would it be useful?
How do I conduct fatigue tests- stress controlled or strain controlled and what loads should I consider?
The first step would be to understand the entire weight of the vehicle and then its distribution i.e. Front & Back . Based on the above data you can calculate the load on each wheel . Once the load is understood then multiply by varioug "g"values to simulate the actual driving conditions such as cornering, latera acc, longitudinal acceleration, braking etc., This is the simplest method to calculate the load on each knuckle.
Road profile data is availbel for various vehicle and road conditions. You have to find the exact applcation and road and in India it is costly to obtain those data.
You can carry out stress controlled fatigue test and there is no need of strain controlled fatigue test.
Hope I have made myself clear.All the best
In case you have the actual vehicle with the desired knuckle mounted, you can strain gauge preferably rosettes across the various arms of the steering knuckle. Collect the strain history and then you can perform the strain calibration in the lab. This way you get the realistic strain which can be converted to loads and cycles for your fatigue testing as well.
This might help: https://www.researchgate.net/publication/279501053_Fatigue_Life_Prediction_and_Durability_test_of_passenger_car_Rheocast_Aluminium_Steering_Knuckle
Article Fatigue Life Prediction and Durability test of passenger car...
If the system you are working is a new one, you have to measure the newly made device with the load cell sensors for the combination of loads acting on it or the system is exist, you would get the load details from the designer ! The fatigue testing shall be similar to the real field conditions and it can be even worsen !
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