Durability Validation of Full Vehicle Structures Using Strain Correlation and RLDA-Based Simulations

Durability validation of full vehicle structures is crucial to ensure long-term performance and structural integrity under real-world loading conditions. Accurate strain correlation between physical testing and finite element (FE) simulations plays a key role in the validation, ensuring reliable predictions of vehicle durability. In this paper, a comprehensive methodology for strain correlation on a full vehicle subjected to torture track testing is implemented. Strategic placement of strain gauges is determined through a combination of static analysis, modal analysis, and identification of critical stress regions in the FE model. Strain gauges were installed on key structural locations of a prototype to capture strain responses under severe loading environments. Simultaneously, vehicle wheel loads were recorded on the torture track to build a detailed Road Load Data Acquisition (RLDA) dataset at critical hard points, Loads measured in terms of wheel loads (WFT) are fed to MBD model to cascade loads at different hard point. These measured loads were subsequently used to perform RLDA-based modal transient fatigue analysis. The findings of this paper establish a robust methodology for improving vehicle durability assessments by enhancing confidence in fatigue life predictions and structural performance. By integrating physical testing and FE simulations, this approach ensures accurate strain correlation and effective validation of long-term performance. It also provides a scalable framework for validating structural changes, supporting lightweight material integration, and enabling Value Analysis/Value Engineering (VAVE) initiatives to optimize cost-effectiveness and performance. This methodology strengthens simulation-driven durability development, offering valuable insights for future vehicle programs.