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The elasto-plastic stress/strain behavior of an automobile rear axle was analyzed by three-dimension finite element method. Based on the stress in critical area where fatigue crack appears, the fatigue life of the welded structure was predicted using the critical shear stress plane criterion. To improve the fatigue property of the rear-axle, the welding-seam was strengthened by both pellet spraying and plasma melting, and evident improvement was experimentally illustrated. Based on the viewpoint that a complex component is also a system in the respect of reliability assessment and statistical dependence among component failures (i.e.the so call “common cause failure”) is inherent for system under stochastic load environment, a system-level load-strength interference model was presented and the reliability of the rear axle was estimated as a system, instead of a component.
The elasto-plastic stress / strain behavior of an automobile rear axle was analyzed by three-dimension finite element method. Based on the stress in critical area where fatigue crack appears, the fatigue life of the welded structure was predicted using the critical shear stress plane criterion for the fatigue property of the rear-axle, the welding-seam was strengthened by both pellet spraying and plasma melting, and evident improvement was experimentally illustrated. Based on the viewpoint that a complex component is also a system in the respect of reliability assessment and statistical dependence among component failures (iethe so call “common cause failure”) is inherent for system under stochastic load environment, a system-level load-strength interference model was presented and the reliability of the rear axle was estimated as a system, instead of a component.