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The use of virtual and / or experimental test rigs applying random loading is becoming more relevant in the development and validation of new products. An application example is the analysis of components subject to vibrations, especially suspended components. For this type of application, product validation applying random loads and different frequencies becomes mandatory. This study developed a virtual test rig for suspended components validation and definition of experimental test rigs. The study was based on a standard component, using LMS Virtual.Lab Siemens software for the dynamic analysis and durability. The experimental data (extensometry and accelerometry) was collected on the special tracks of Randon Companies Proving Ground. From the virtual modeling and experimental data, the proper hydraulic actuators signals were defined to characterize the component behavior according to the field application.

Applying knowledge available at technical literature for cycle counting, damage caused by each load cycle through S-N curve, and fatigue damage accumulation by Palmgren-Miner rule, durability prediction is performed for a leafspring of a commercial vehicle with 6×4 suspension system. Max principal tension is measured by means of strain gages in the most representative points for fatigue life of the leafspring, determined with FEA, while vehicle runs over off-road track in a proving ground. Load and tension are also measured in a laboratory bench test for this component. Correlation between off-road track and bench test is then performed. Finally, representative samples of the component are tested with dynamic loading until fatigue fracture in bench test, and using data from these tests, statistical analysis is performed with application of Weibull distribution, allowing life prediction in statistical terms.