Failure analysis of kingpin hole on front axle of mining truck based on finite element analysis

•Based on finite element analysis, the cause of fatigue failure of the front axle of mining trucks was found.•Combined with computer software and test verification, the fatigue life is predicted quickly and accurately.•The structure has been improved to address the causes of fatigue failure. The axle is a critical load-bearing component of a vehicle, and its failure can lead to serious accidents. During a vertical fatigue test, the front axle of a mining truck failed prematurely. To identify the cause of this failure and enhance the structural design to meet technical requirements, a stress analysis was conducted using the finite element method. The analysis revealed areas of stress concentration on the front axle. The mechanical properties of the material were determined through tensile testing. A fatigue life analysis method, based on finite element analysis, was employed to assess the axle’s fatigue life. This method identified the location where fatigue cracks initiated and determined the minimum load cycles before the onset of fatigue cracking. The results were then compared with actual observations. Following improvements to the design based on the simulation results, another round of fatigue analysis was performed. The findings indicated a significant increase in the axle’s fatigue life, thereby meeting the required technical standards.