Mathematical Modeling and Simulation of Wheel Hub Stresses Using Finite Element Analysis in Light Military Trainer Aircraft

The landing gear of modern aircraft accounts for approximately 20% of the structural weight and 5% of the total weight. Among its components, the wheel hub endures particularly high loads during landing, often leading to cracks and porosity associated with casting-induced micro-voids in magnesium and aluminum alloys. Over time, cyclic stresses enlarge these voids, converting them into critical stress concentrators. Differences in alloy properties, such as yield strength, fracture toughness, and corrosion resistance, further influence how cracks propagate, underscoring the importance of rigorous manufacturing methods and regular nondestructive inspections. To investigate these vulnerabilities, stress analyses were performed on a military trainer aircraft wheel hub through finite element simulations under static loads. This modeling approach simplified the system while still ensuring conservative predictions of landing gear reactions and safety margins. Notably, the predicted high-stress regions corresponded to dye penetrant testing results, where surface cracks were detected, thus validating the numerical findings. The outcomes also met relevant regulations of FAR Section 23.473 (“Ground Load Conditions and Assumptions”), showcasing how thoughtful design choices and material oversight can improve operational reliability, especially for aircraft operating on varied or unpaved runways. By providing a comprehensive overview of the wheel hub’s mechanical behavior under static conditions, this study bridges gaps in the existing literature and advances knowledge in materials engineering and structural mechanics. Altogether, it highlights how judicious material selection, strict manufacturing controls, and ongoing inspections together sustain aircraft performance and safety, even under demanding landing conditions.