Numerical Analysis of the Impact of Internal Defects on the Mechanical Properties of Solid Axles under Combined Bending and Torsion

The detection and characterization of internal defects in solid components is crucial for ensuring structural integrity and safety in various engineering applications. This study investigates the influence of internal annular sector-shaped defects on the mechanical behavior of circular solid shafts under combined bending-torsion loading. The research methodology involved developing finite element models with and without internal defects, representing a bending-torsion testing setup. Numerical simulations were performed to analyze the stress distribution, deformation patterns, and reaction forces under various loading conditions. The results revealed that the presence of internal defects significantly alters the stress distribution, leading to localized stress concentrations near the defect location. Furthermore, the maximum Mises stress values were consistently higher in the model with internal defects compared to the defect-free model. The constraint reaction force analysis demonstrated a reduction in mechanical resistance due to internal defects, resulting in lower reaction force values. The main conclusion drawn from this study is that the presence of internal defects has a profound impact on the mechanical behavior of solid shafts under combined bending-torsion loading. The observed variations in stress distribution, maximum Mises stress, and reaction forces offer potential avenues for detecting internal defects based on bending-torsion deformation. These findings contribute to the development of reliable non-destructive testing techniques for ensuring the structural integrity of critical components.