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• The intent of PD is that all potential failures modes that we design against are discovered
and fixed before Job #1.
• We accept that we cannot possibly design for every single customer. Therefore we define
the usage spectrum corresponding to 90% of the customers as our target for wear out
failures.
Potential Failure Modes and Their Relationship to
Strength and Fatigue Requirements
Failure
Rate “Design for Fatigue”
Identify and design against all
• The “Fatigue Requirements” cover the usage spectrum of 90% of the customers
• The “Strength Requirements” cover “extreme duty” customers as well as “random” events.
Failures are possible, and the intent is to develop fail-safe designs.
• During product development, laboratory tests at component and system levels are employed as
early as possible to “front-load” the discovery of strength and fatigue failure modes (as opposed
vehicle tests in the proving ground)
Methods of Durability Testing
• FE & fatigue analysis of complete body/chassis
system subject to duty cycle
• Lab testing of the vehicle
• Vehicle testing on the proving ground
• Vehicle fleet testing on public roads
Laboratory Testing
Proving Ground Testing
Force ,F
Force ,F
Fixed Fixed
Load
N0 Cycles, N
S-N Curve for Metals
45
40
(Engg.) Stress Range, KSI
35
30
25
20
15
10
0
1.E+00 1.E+01 1.E+02 1.E+03 1.E+04 1.E+05 1.E+06 1.E+07
Rule of Thumb for Fatigue Design: - 5 to -10% Stress => +100% Life
To increase Fatigue Life, increase the strength of the part without inflicting
surface damage. Fatigue begins at stress concentrators which are most
frequently located on surfaces
Time
Time
Load Histogram
Load
Cycles
Fatigue Damage Calculation
S1
S2
S3
Stress
S4 Stress Histogram
S5
S6
N1 N2 N3 N4 N5 N6 Cycles
50
35
Stress
30
25
20
6
15
Damage D = Σ N(σi)/Ni
10 1
5
0 And D < 1
1.E+00 1.E+01 1.E+02 1.E+03 1.E+04 1.E+05 1.E+06 1.E+07
Cycles
Process to Evaluate Structural Durability
Road Surface,
Speed and
Number of Passes
Suspension Load
Histogram for
Components
Component
Stress
Histogram
Damage Calculation
from Material
S-N Curve
Durability Road Surface
• Severe pothole – 1 pot hole per how many miles (N)
• Severe bump - 1 bump per how many miles (N)
• Cobble stone - 1 cobblestone per how many miles (N)
• Etc.
Shock Load
1000 2000 1.5 750 2000 1
Sprung
corner wt 400 kg
Unsprung Whl speed
weight 40 kg
Road
Profile
Whl Load
Tire Load
Rim
Tire Contact
Lift-off
Tire Compression Whl Deflection
Jounce Fender
Clearance
Tire
Small Car 50 mm
Large Car 90 mm
Big SUV 120mm
Truck 150mm
Suspension Loads
S4 Stress Histogram
S5
S6
N1 N2 N3 N4 N5 N6 Cycles
50
35
Stress
30
25
20
6
15
Damage D = Σ N(σi)/Ni
10 1
5
0 And D < 1
1.E+00 1.E+01 1.E+02 1.E+03 1.E+04 1.E+05 1.E+06 1.E+07
Cycles
Procedure