Predicting Stress Intensity Factor for Aluminum 6062 T6 Material in L-Shaped Lower Control Arm (LCA) Design Using Extended Finite Element Analysis

The aim of this study is to solve a practical problem encountered in the automotive industry, especially the failure of a cracked lower control arm made of al 6062 T6 material during static and crash physical tests, and to characterize the behavior of cracked parts made of aluminum materials using the fracture mechanics parameters. As a first step, we carried out a numerical study and simulation using Abaqus/CAE 2020 software and the finite element method to determine the stress concentration and load limit capacity for different car weight cases. The von Mises stress variation shows crack initiation and propagation to be in the area of the lower control arm’s attachment to the vehicle platform, where stress is concentrated. These numerical results are consistent with the experimental test results found by automotive manufacturers. Also, we find that the mechanical load that can support this part is below 4900 N for good performance. In the second step, we use the results of the first section to simulate the failure of a lower control arm with a crack defect. This paper investigates the stress intensity factor KI in mode I for different lengths (L) and depths (a) of the crack in the lower control arm using the extended finite element method (XFEM) under Abaqus/CAE. For crack failure initiation and progression, we relied on the traction separation law, specifically the maximum principal stress (MAXPS) criterion. The KI factor was evaluated for the materials steel and Al 6062 T6. The results obtained from the variation of the KI coefficient as a function of crack depth (a) and the thickness (t) show that the crack remains stable even when a depth ratio (a/t = 0.8) is reached for the steel material. However, the crack in the Aluminum 6062 T6 material becomes unstable at depth (a/t = 0.6), with a high risk of total failure of the lower control arm.