Correlation of Fatigue Test Results and Finite Element Analysis for a Prototype Independent Suspension Axle Housing

This paper reports on the correlation of fatigue results with Finite Element Analysis (FEA) predictions for an axle housing designed as an integral part of an independent suspension for an off-road truck.

The axle initially failed to meet the prescribed fatigue performance criteria and a description of the failures is given. Maximum permissible stress levels were estimated for the prescribed performance. Linear FEA was used to determine the stresses in the original axle housing that had failed the fatigue test. Analysis of the available fatigue data predicted component life that was in good agreement with the test results.

Further FEA allowed the effectiveness of design modifications to be monitored, resulting in a new design having a high degree of probability of meeting the fatigue performance criterion, without increase in weight, and at a lesser cost than repeated testing.