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Modern fatigue analysis techniques, that can provide reliable estimates of the service performance of components and structures, are finding increasing use in vehicle development programs. A major objective of such efforts is the prediction of the field performance of a fleet of vehicles as influenced by the host of design, manufacturing, and performance variables. An approach to this complex problem, based on the incorporation of probability theory in established life prediction methods, is presented. In this way, quantitative estimates of the lifetime distribution of a population are obtained based on anticipated, or specified, variations in component geometry, material processing sequences, and service loading. The application of this approach is demonstrated through a case study of an automotive transmission component.

The incorporation of reliability theory into a fatigue analysis algorithm is studied. This probabilistic approach gives designers the ability to quantify “real world” variations existing in the material properties, geometry, and loading of engineering components. Such information would serve to enhance the speed and accuracy of current design techniques. An automobile wheel assembly is then introduced as an example of the applications of this durability/reliability design package.

A concise method for modeling nonstationary fatigue loading histories is presented. The mininum number of model parameters is achieved by fitting the variations in mean and variance by a truncated Fourier series. An autoregressive moving average (ARMA) model is used to describe the stationary component. Justification of the method is made by comparing fatigue relevant parameters obtained when subjected to the original and reconstructed histories. In spite of a relatively small number of parameters required, the model is shown to give good results that fall within the bounds predicted by the orginal history.

Fatigue characteristics of representative cold-rolled, high strength steels, in gages ranging from 0.072 in. (1.83 mm) to 0.055 in. (1.39 mm), were determined in fully-reversed, axial strain cycling at amplitudes up to 0.01. Alloys were selected from three families of high strength steels: recovery annealed steels, conventional microalloyed steels - nitrogenized steel and rephosphorized steel, and dual phase steel. Cold rolled low-carbon steel provided a comparative baseline. Cyclic stress-strain curves are presented to indicate the degree of cyclic stability achievable by various strengthening mechanisms while relative fatigue resistance is determined from strain-life curves. The implications of these behavioral trends to component down gaging are discussed.

Significant progress in materials and structures research leading to improved analytical and experimental capabilities for evaluating the mechanical durability of automotive structures is reviewed. Recent experiences in incorporating modern fatigue analysis methodology in easily used computer-based formats are then presented. This is followed by a general discussion of the application of design aids at various points in the product development cycle with emphasis on future trends and needs.

An overview of the current status and emerging trends in durability-related technologies is presented as an introduction to a series of papers covering applications of durability analysis in design. Problems of information management associated with technology integration are discussed along with the probable impact of new design tools on product development and validation.