Investigation of Fatigue Failure Mechanisms in High-Pressure Hydraulic Pipes of Power Steering Systems Tata Motors, Limited

Format:

Book

Conference/Event

Author/Creator:

Survade, Lalit, author.

Contributor:

Biswas, Kaushik

Koulage, Dasharath Baliram

Conference Name:

Symposium on International Automotive Technology (2026) (2026-01-28 : Pune, India)

Language:

English

Physical Description:

1 online resource cm

Place of Publication:

Warrendale, PA SAE International 2026

Summary:

The high-pressure steering hose in a hydraulic steering system carries pressurized hydraulic fluid from the power steering pump to the steering gear (or steering rack). Its main function is to transmit the force generated by the pump so that the hydraulic pressure assists the driver in turning the wheels more easily. The high-pressure hydraulic pipeline in the power steering system is a vital component for ensuring optimal performance. During warranty analysis, leakage incidents were observed at the customer end within the warranty period. The primary factors contributing to these failures include pipe material thickness, material composition, mechanical properties, and engine-induced vibrations. This study investigates fatigue-related failures through detailed material characterization and Computer-Aided Engineering (CAE) based on real world usage road load data collected. The objective is to identify the root causes by examining the influence of varying pipe thickness on fatigue life.The investigation discovered that crack initiation predominantly occurred on the concave side of bent pipe sections, specifically on the engine-side high-pressure steering line, which is connected to the power steering pump mounted on the engine. Fracture surfaces exhibited characteristics consistent with fatigue failure, with crack propagation primarily oriented longitudinally along the pipe. The highest tangential stresses were observed on the out word, resulting from the combined effects of internal hydraulic pressure and vibrational loads. Fatigue cracks originated from the inner surface and propagated outward under cyclic stresses induced by pressure fluctuations and engine vibrations during vehicle operation on the road.Computer-Aided Engineering (CAE) simulations indicated that the failure mechanism was primarily attributable to an incorrect material thickness selection during the development phase. Modifications to the pipe design, including increased material thickness, were implemented, leading to improved performance in subsequent testing. The high-pressure hydraulic pipeline exhibits decreased failure rates and improved reliability and durability following the implementation of the revised design

Notes:

Vendor supplied data

Publisher Number:

2026-26-0542

Access Restriction:

Restricted for use by site license