Effect of Residual Stresses on Wheel Fatigue Life and Experimental Validation

Steel wheels, consisting of rims and spokes, are important load-bearing parts of vehicles, and the fatigue fractures’ life estimation accuracy directly determines the stability and safety when applied in the transportation industry. The most common form of failure is fatigue fracture. The strong elastic–plastic deformation during the rim roll-forming process generates a residual stress field in its surface layer, which changes the actual stress distribution in the rim when it is loaded and thus affects the fatigue life of the steel wheel. In this paper, ABAQUS software was used to establish a rim-rolling simulation model to obtain the residual stress field distribution after forming and compare it with the actual residual stress on the formed surface of the rim to verify the reliability of the model. On the basis of this model establishment, the service hazard areas and maximum stresses of steel wheels with or without superimposed residual stress fields were calculated separately, and their fatigue lives were predicted separately using the local stress-strain method. The simulation results show that the maximum stress of the rim before and after the superimposed residual stress occurs in the area of the bottom of the groove, which is consistent with the actual failure location. However, the maximum stress after superposition increased from 120.7 MPa to 332.9 MPa, and the corresponding calculated life decreased from 158,340,000 to 459,500 cycles, which is closer to the actual test results. The results of the study can provide a theoretical basis for the lightweight design and process improvement of automotive steel wheels.