Fatigue Life Prediction Methodology for Vehicle Suspension Systems and Correlation with Physical Test Tata Technologies, Limited

Format:

Book

Conference/Event

Author/Creator:

Kokare, Sanjay, author.

Contributor:

Iqbal, Shoaib

Nagapurkar, Tejas

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:

Fatigue analysis is a vital aspect of suspension design, especially for load bearing components such as the Rear Twist Beam, where durability under cyclic loading is essential for long-term vehicle performance. Among the various durability tests, the roll fatigue test is a key procedure for validating suspension strength and reliability. However, conducting physical roll fatigue tests can be both expensive and time consuming, particularly when multiple design iterations are required. This not only increases cost but also extends the development timeline. This study presents a virtual simulation methodology that replicates roll fatigue test conditions within a finite element analysis environment, enabling early fatigue assessment and design optimization. Developed to support the early design phase, the roll fatigue test simulation process ensures robust designs that meet targeted fatigue life requirements. The approach begins with a detailed understanding of the physical roll fatigue test setup, which is then reproduced through Finite Element Analysis to closely match real test conditions. Enforced displacement applied at wheel center according to duty cycles, and boundary conditions are defined to match those of the physical test. Cumulative damage is then calculated in fatigue solvers to predict the fatigue strength of the components. The methodology is validated by correlating results with physical test data. This approach enables early detection of potential fatigue-critical areas, supports design optimization, and reduces both development cycle time and cost by minimizing physical testing. As a result, development cycles are shortened, costs are lowered, and durable, manufacturable designs can be achieved earlier in the product development process

Notes:

Vendor supplied data

Publisher Number:

2026-26-0459

Access Restriction:

Restricted for use by site license