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The design of wheel hubs must be based on stresses generated under customer usage through operational loads acting on the wheel. Therefore, the service loading conditions must be taken into account as well as the generated stresses and the hub fatigue properties. In this paper the decisive parameters for design and durability - operational loads, fatigue properties, which depend on material and manufacturing technology, and design - are discussed and the procedure for an optimum light-weight design is treated. Finally, the test procedure for durability approval, the corresponding test facility, the test programs and requirements, and some typical test results are presented.

Leaf springs must be regarded as safety components of a vehicle which failures can cause severe accidents. They have to fulfill various functions as a spring element and for guiding the axles and are also responsible for driving comfort. Therefore, the durability approval must be carried out under representative service-like loading, which take into account complex leaf deformations in operational usage. In this paper the influencing parameters for the durability approval of leaf spring suspensions are discussed and the test rig and the standardized test program SPRILOS (SPRIng LOad Sequence) for the durability approval are described.

The validation of the wheel/hub assembly has been carried out in the Biaxial Wheel/Hub Test facility since the early ‘1980’s developed at Fraunhofer LBF. This test procedure became a standard at most of the European wheel and truck producers and was also introduced as SAE wheel standard J 2562, issued in 2003. For newly developed Super Single low profile tires 495/45R22.5, which will replace double rear tires on heavy trucks and buses, the corresponding steel and aluminum wheels had to be designed by the suppliers. Because of the lack of information about load data and load programs for testing, extensive research had to be undertaken. The load data had been measured in collaboration with DaimlerChrysler on a M.B. Actros on proving grounds and on the “Black Forest round track” in Germany. Based on the derived data a special “Eurocycle” load program has been developed for accelerated testing of the wheels in the Biaxial Wheel Test Rig.

The method of fatigue life evaluation and validation testing under operational conditions is a prerequisite to achieve optimal designs with respect to weight and long-term durability of the structure considered. Criteria like driving behavior and braking performance, influenced by global stiffness as well as fatigue life evaluation were taken into account when optimizing a forged 6.5 front axle beam of a heavy truck. The procedure for weight optimization includes the following steps: Stress analysis e.g. using strain gage techniques and/or Finite Element Method, Road load data acquisition and derivation of design spectrum describing customer usage, Fatigue testing under constant amplitude and/or variable amplitude loading to establish component related SN-curves and/or fatigue life curves, Fatigue life evaluation using damage accumulation hypothesis (Miner's Rule), Optimization and weight reduction (in this case 14% weight savings were achieved) based on fatigue life evaluation.

Air spring systems are increasingly used on suspensions for commercial vehicles. To prove their durability a reliable test procedure is necessary: to be applied already in the development stage to be used to qualify individual air spring manufacturers and to assure manufacturing quality. In this paper the test procedure, the test facility and some test results are presented. In the test facility the air spring is mounted on a fixture and is loaded by a servohydraulic actuator. The mounting of the air spring allows to simulate all operational deformations, being decisive for the durability. Based on the extensive measurements on proving ground and public roads the test program was worked out. The test program includes besides the loading and deformations during driving also kneeling operations as well as high and low temperatures. The accelerated laboratory tests deliver results which correspond to the existing experience at the service usage.