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In this paper, resonance durability analysis is performed for the fatigue life assessment of suspension component considering the dynamic effect of vehicle system. In the resonance durability analysis, the frequency response data and the dynamic load data of frequency domain are used. The multi-body dynamic analysis, finite element analysis and fatigue life prediction method are applied for the resonance durability analysis. To obtain the dynamic load history, the computer simulations running over typical pothole and Belgian road are carried out respectively by utilizing multi-body dynamic vehicle model. The durability estimation for the rear suspension system of the small-sized passenger car is performed by using the resonance durability analysis technique, and the estimation result is compared with the quasi-static durability analysis result. The study shows that the fatigue life considering the resonance frequency of vehicle system can be effectively estimated in early design stage.

Design for six sigma (DFSS) with sigma based robust design will have a major influence on the future design, if it is applied during the conceptual design phase or design change phase. DFSS will result in more improved but less expensive quality products. This paper presents the implementation of DFSS for robust design of a brake judder of heavy-duty trucks. The problem of brake judder is typically caused by quality defects in manufacturing. However this quality problem can't be controlled deterministically and requires a design considering the uncertainty. In this paper sigma based robust design methodology is applied to improve the brake judder quality problem at the last step of DFSS. Results between conventional deterministic optimization and the proposed sigma based robust design are compared. The robust design by DFSS shows that the manufacturing cost may increase as the quality level increase.