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The structural calculation of a complete light truck frame using the Finite Element Method requires the knowledge of the torsional stiffness of the cargo box, cab and front end of the vehicle. This paper presents a practical way to obtain the necessary data, avoiding the mathematical modeling of the whole vehicle, to reduce time and machine requirements. Lab measurements of the torsional stiffness are performed, in the frame alone and with each of the body components, allowing the definition of a mathematical model for the whole vehicle.

An improved procedure to structurally certify medium and heavy trucks has been introduced to reduce development and certification time, as well as to increase design confidence. The new procedure is based on finite element stress analysis (FESA), laboratory tests, data acquisition, and vehicle durability tests. The vehicle structural durability test has been one of the most time demanding items of a truck program. An accelerated route has been developed, based on data acquisition and correlation analyses, halving the test time and cost.