Criteria and Methodology for Lightweight Design of Vehicle Components Subjected to Random Loads

The methodology “Service Strength Analysis” is discussed. The method allows design optimization of lightweight vehicle components whereby not only the required service life but also adequate reliability and safety are taken into account. While the service life depends primarily on operational loading, design as such, material and manufacturing processes, reliability and safety requirements depend on the function of the component. The methodology comprises stress analysis under service loading, derivation of stress spectra, strength evaluation and proof-out testing under simulated service load spectra.

The method allows to determine not only areas critical to fatigue strength but also areas that are overdimensioned, where weight and cost may be saved. The methodology reduces development time, saves material and may improve manufacturing. As the method is being applied, data regarding product liability are collected automatically.