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<p>Sheet metals are extensively used in the manufacture of automotive components due to their favorable mechanical properties, including hardness, strength, frictional behavior, and wear resistance. In the present study, five commonly used automotive sheet metal grades SAPH440, CR2D, D HR2, Fe510, and Fe410 are selected for a comparative investigation using both structural analysis software and an experimental pin-on-disc setup. The experimental investigation is conducted under dry sliding conditions using a pin-on-disc wear testing apparatus. Tests are performed at a constant rotational speed of 50&#xa0;rpm under applied loads of 6&#xa0;kg, 10&#xa0;kg, 14&#xa0;kg, and 18&#xa0;kg. D2 steel is employed as the disc material, while SAPH440, CR2D, D HR2, Fe510, and Fe410 are used as pin materials. The selection of these sheet metals is based on insights derived from Product Failure Mode and Effects Analysis (PFMEA) and Process Failure Mode and Effects Analysis (PFMEA), ensuring their industrial relevance and suitability for automotive applications. Following the experimental investigation, the wear behavior and performance trends obtained from the pin-on-disc tests are validated through numerical simulations using ANSYS software. Both experimental and simulation results consistently indicate that the SAPH440 grade exhibits superior performance, demonstrating the lowest wear rate and, consequently, the maximum component life compared to the other investigated sheet metal grades.</p> Graphical Abstract <p></p>

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Structural and Tribological Evaluation of Automotive Sheet Metals for Enhanced Component Life

  • 期刊论文

  • 发表日期：

    2026年7月10日

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  • Kiran S. Phad,
  • Anurag Hamilton,
  • Umesh Gurnani,
  • S. H. Gawande

摘要

Sheet metals are extensively used in the manufacture of automotive components due to their favorable mechanical properties, including hardness, strength, frictional behavior, and wear resistance. In the present study, five commonly used automotive sheet metal grades SAPH440, CR2D, D HR2, Fe510, and Fe410 are selected for a comparative investigation using both structural analysis software and an experimental pin-on-disc setup. The experimental investigation is conducted under dry sliding conditions using a pin-on-disc wear testing apparatus. Tests are performed at a constant rotational speed of 50 rpm under applied loads of 6 kg, 10 kg, 14 kg, and 18 kg. D2 steel is employed as the disc material, while SAPH440, CR2D, D HR2, Fe510, and Fe410 are used as pin materials. The selection of these sheet metals is based on insights derived from Product Failure Mode and Effects Analysis (PFMEA) and Process Failure Mode and Effects Analysis (PFMEA), ensuring their industrial relevance and suitability for automotive applications. Following the experimental investigation, the wear behavior and performance trends obtained from the pin-on-disc tests are validated through numerical simulations using ANSYS software. Both experimental and simulation results consistently indicate that the SAPH440 grade exhibits superior performance, demonstrating the lowest wear rate and, consequently, the maximum component life compared to the other investigated sheet metal grades.

Graphical Abstract