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Fatigue life predictions using the strain-life method are used in the design of modern light weight vehicle, for the complex loading that occur with the structural durability tests that these vehicles undergo. The accuracy of these predictions is dependent upon the many factors; geometry, loads & materials etc. This paper details a new procedure to ensure the quality and accuracy of the material parameters for the fatigue life prediction software. The material parameters for the solver are obtained by performing strain-controlled fatigue tests. The geometry of the coupons tested is determined by size and thickness of the material specimen that they are machined from and the loading regime in the test. Detailed data analyzed is conducted on these tests and the parameters that are used as input into the CAE strain-life fatigue prediction software are generated.

As revealed from J. D. Power surveys, today most vehicle owners consider perceived quality as a direct indicator of the vehicle build quality and durability. [5] The problem has become more prominent and noticeable in recent times, due to the desire for reduced cost, reduced weight targets, aesthetic demands, and crash requirements. The performance of the door assembly when subjected to an abuse load of sag and over opening is one such perceived quality indicator which gives the customer the first impression about the engineering and build quality of the vehicle. Door hinge inclination and hinge contact flushness tolerance are the major design parameters affecting this performance. Although these are an important design parameter, the precise quantification of the effect of these design parameters on door performance under abuse loading has remained somewhat elusive.