Simulation of Initial Cracks in Truck Wheel Drive Axle Flange Fillets Using the Finite Element Method

Abstract

Langsa residents rely on trucks as the main means of transporting palm oil from plantations. In mechanical systems, component failures often occur, often characterized by the breakdown of a particular part. Cracks are a key factor contributing to failure in machine structures. Early detection of cracks in shafts is critical to reducing damage, requiring the use of appropriate methods in the early stages of crack formation. This research aims to analyze the effect of crack initiation in truck drive axle flange fillets on stress and strain distribution using the finite element method. The simulation results show that the maximum shear stress in the area without cracks ranges from 0.0032 to 61.282 MPa, while after crack initiation, the shear stress value increases to 70.036 to 78.79 MPa. Likewise, the Von Mises stress increased from 0.006 to 106.74 MPa to 121.99 to 137.23 MPa after the crack was modeled. In addition, the maximum shear strain increased from 7.506×10⁻⁸ - 5.389×10⁻⁴ to 6.159×10⁻⁴ - 6.929×10⁻⁴ in the cracked area. These increases in stress and strain values indicate that the initial crack increases the stress concentration and local deformation, which accelerates the accumulation of structural damage in the shaft. This research emphasizes the importance of early crack detection and design strengthening to prevent structural failure in truck drive axle components.