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Durability of automobile stabiliser bar is assessed in the present study. Finite element analysis of the stabiliser bar is performed based on the experimental observations. Fatigue analysis is performed under cyclic loading. Fatigue analysis is performed for maximum cyclic loading conditions. Improvement is the fatigue life of stabilizer bar is analysed by shot peening. Special purpose machine is used to simulate the fatigue life of stabilizer bar. Commercial software ABAQUS is used for numerical simulation. Computational fatigue simulation software, fe-safe is used for the fatigue analysis to predict the fatigue life (number of cycles for crack initiation) and crack site location. Predicted results were compared with that of the physical test results for validation.

In this paper, the application of tube Extrusion for the development of stepped tubular components is discussed. Thickness increase with respect to cold reduction of diameter is predicted with reasonable accuracy. Thickness increase, length increase and strain hardening coefficient for a given cold reduction of diameter of tube are obtained using LS-DYNA Software. True stress-plastic strain curves from the tensile test are used in the forming simulation using LS-DYNA. A special purpose machine is developed for the production of steering shaft components. Considerable reduction in weight is achieved by using stepped tubular components.