Authors : Abish Paudel; Bikash Mehta; Dr. Soondo Kweon; Dr. Fengxia Wang; Dr. Kamran Shavezipur

Volume/Issue : Volume 10 - 2025, Issue 5 - May

Google Scholar : https://tinyurl.com/3yy9rvet

DOI : https://doi.org/10.38124/ijisrt/25may769

Note : A published paper may take 4-5 working days from the publication date to appear in PlumX Metrics, Semantic Scholar, and ResearchGate.

Abstract : The front axle is a critical structural component in vehicles, playing a pivotal role in supporting weight, facilitating steering, and absorbing shocks from uneven surfaces. Constructed from high-strength materials like steel or alloyed metals, its design varies based on vehicle type and performance requirements. This study specifically focuses on the front dead axle used in rear-wheel-drive vehicles, which serves as a structural support and steering mechanism without transmitting driving torque. Emphasis is placed on understanding the mechanical behavior of the front dead axle under extreme loading conditions, particularly during a frontal crash scenario with a load equivalent to 5G. The axle’s structural components— such as the main beam and kingpins—are analyzed for their role in ensuring safety and stability. In this paper, structural analysis of the front axle is conducted using ABAQUS with a crash load of 5G to the front-end of the front axle. An optimized front axle is designed and further FE (Finite Element) analysis is performed. Static FE analysis is performed on a CAD (Computer Aided Design) model and the performance in both elastic & elastoplastic cases are checked. The results indicate that an optimized design reduces the maximum stress experienced by the axle, thereby increasing the factor of safety. With a factor of safety equal to or greater than 1 under a reduced crash load of 5G, the study confirms the axle’s ability to withstand severe loading scenarios. Validation of the Abaqus result is done with a MATLAB FE code, which is developed in this study and the Abaqus results are in agreement with the MATLAB FE code result. This research underscores the value of FEA in guiding design optimization, enabling safer and more efficient vehicle components through simulation-driven engineering.

References :

1. Min Zhang, Xiangfei Ji, Lijun Li, “A research on fatigue life of front axle beam for heavy duty truck”, Advances in Engineering Software 91(2016): 63-68
2. Shwetank Avikal, Atul Bisht, Devender Sharma, Himanshu Hindwan, Siddharth Yadav, K.C. Nithin Kumar, Padmanabh Thakur, “Design and fatigue analysis of front axle beam of a heavy duty truck using ANSYS”, Materials Today: Proceedings 26(2020) 3211-3215
3. M.M. Topac , H. Gunal , N.S. Kuralay,“Fatigue failure prediction of a rear axle housing prototype by using finite element analysis” , Engineering Failure Analysis 16 (2009) 1474–1482 
4. Hemant L. Aghav, M.V.Walame,“ Stress Analysis and Fatigue Analysis of Front Axle of Heavy-Duty Truck using ANSYS Ncode Design Life for Different Loading Cases”, Int. Journal of Engineering Research and Application ISSN : 2248-9622, Vol. 6, Issue 6, ( Part -2) June 2016, pp.78-82
5. Zheng B, Fu S, Lei J,“Topology Optimization and Multiobjective Optimization for Drive Axle Housing of a Rear Axle Drive Truck.” Materials (Basel). 2022 Jul 30;15(15):5268. doi: 10.3390/ma15155268. PMID: 35955204; PMCID: PMC9369993.
6. Pratyush Deshmukh, Lohit Kumar, Dixit Kumar Maradia and Gunchita Kaur Wadhwa “TOPOLOGY OPTIMIZATION OF REAR AXLE OF HEAVY VEHICLE.” International Journal of Mechanical Engineering and Technology (IJMET) Volume 9, Issue 4, April 2018, pp. 953 959
7. Nikita A Duble, A. D. Diwate “Design and Finite Element Analysis of Differential Cover for Rear Drive axle of a Light Commercial Vehicle (LCV).” International Journal of Analytical, Experimental and Finite Element Analysis Vol. 7, Issue. 2, July 2020, pp 53 – 60.
8. Sainadh, A. A. (2018). DESIGN, ANALYSIS & OPTIMIZATION OF FRONT AXLE IN ELECTRIC VEHICLES. INTERNATIONAL JOURNAL OF ENGINEERING SCIENCES & RESEARCH TECHNOLOGY, 7(8), 557-567.
9. N. León, O. Martínez, P. Orta C., P. Adaya,” Reducing the Weight of a Frontal Truck Axle Beam Using Experimental Test Procedures to Fine Tune FEA.  MSC Automotive Conference., 2000
10. K.V. Dhande, P. Ulhe, “Design and analysis of front axle of a heavy commercial vehicle”, E3S Int. J. Sci., Technol. Manage. (2014), pp. 114-122
11. M.M. Topic, S. Ercan, N.S. Kuralay “Fatigue life prediction of a heavy vehicle steel wheel under radial loads by using finite element analysis” Eng. Fail. Anal., 20 (2012), pp. 67-79