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This article describes a numerical methodology, based on Finite Element approach, able to simulate, with a unique solution, the dynamic and structural response of a full vehicle running on fatigue reference roads. The current durability process is a multidisciplinary one based on a combination of three different phases: load definition, stress definition, and fatigue life prediction. For Long-Time Histories events, the second phase of this process is necessarily based on a Linear assumption using a Static or Dynamic approach. However, in durability events, some situations can lead the material to work in the plastic range, thus putting on the top the strength aspect of the performances and making these phases not independent and sequential, but strongly interdependent. The goal of the methodology reported in this article is to merge, in a unique numerical simulation, the load and stress definition phases.

This work describes a numerical methodology based on the Finite Element approach able to simulate the dynamic maneuver of the full vehicle running on fatigue reference roads. The basic idea of present work stays in combining a moderately complex and general finite element tire model with traditional full-vehicle methods, including both implicit and explicit finite element techniques, in order to predict the dynamic response of the car running on the real fatigue reference roads. Some issues related to application of tire finite element model to a long simulation time in an explicit solution have been discussed. The best integration strategy between implicit and explicit solutions, based on pure sequential and/or the combined sequential and co-simulation mode is discussed. The real fatigue load is digitalized and implemented as a rigid body in the explicit code.

This work describes numerical methodologies used for both fatigue life prediction and impact load analysis of automotive suspension components made of a cast aluminium alloy. Some issues related with finite element (FE) discretization are discussed, and the main guidelines for fatigue analysis and critical load determination are presented. FE stress results have been validated through comparison with experimental strain gauges measurements, and a good agreement is shown between the predicted fatigue and impact behaviour of the component, and experimental data obtained from bench tests. Such an agreement concerns, in particular, the failure locations, the fatigue lifetime, the critical load and the post-buckling behaviour.