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Fatigue design has to account for the scatter of component geometry, material behavior and loading. Scatter of the first two variables is mainly due to manufacturing and material sourcing. Loading on the other hand depends decisively on operating conditions and customer usage. Loading is certainly most difficult to determine. Tests on proving ground or even long-term real time measurements are used to obtain actual load time histories. Because of the costs of measurements and safety measure, real-time measurements are used exceptionally to gain changes in the usage profile. In this paper, an attempt has been made to find the difference in the extrapolated data to the actual data. A comparison has been made between the actual road distance of 2000 km to the extrapolated data of 100 km, 500 km and 1000 km to 2000 km. The front Axle channel is taken for the study.

Automotive Industry Standard (AIS)-031 specifies the requirement of strength of large passenger vehicles in case of rollover. In India the certificate is granted after the successful completion of rollover test of the vehicle as per AIS-031. Complete vehicle is used for rollover test in which the vehicle is tilted laterally in the ditch of 800 mm. Such tests with complete vehicle are costly and unaffordable to small bus body builders. So according to Annex 2 of AIS-031, manufacture can carryout rollover on body sections of the vehicle. This is an equivalent approval method which is less costly compared to rollover test on complete vehicle. It requires detailed study of superstructure and selection of weakest body sections from the given superstructure of bus, which in turn requires mass and energy calculation of body section. For doing rollover analysis using body section, bus is selected which has already passed a full-rollover test.