Design Optimization of Automobile Rear Axle Housing for Fatigue Loads using Finite Element Analysis

Rear axle housing takes the load of chassis through leaf spring arrangement. Also houses the differential and rear axle drives. The housing is subjected to various structural loads during movement of automobiles. Now-a-days design optimization is becoming important in the analysis as the cost plays an important role in the overall cost of the structure along with higher dynamic effects with heavier structures. Fatigue is the failure of the structures under repeated loads. Due to road conditions, the rear axle housing is subjected to flexuating loads continuously. In the present work, a Rear axle housing used for a truck system will be initially analysed for static loads. This check allows the problem for minimum static structural strength. Later the housing will be analysed for fatigue loads. The weak regions of the rear housing will be identified and suggestions will be done to improve the structure. Final iterated value of 79Mpa is close to the allowable limit of 86.3Mpa of the given material. All the results are represented with necessary graphical plots.