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Evaluation of structural durability has always been a key issue in product development. It is a time consuming element in the development cycle. Exploring fatigue life prediction analysis capabilities, using computer based digital processing techniques, at an early design stage can reduce the development period dramatically. Fatigue sensitivity is an analysis tool to evaluate effect of a design parameter on durability of the component or product under study. The technique was effectively used to analyse parameters like stress concentration, welding geometry, loading environment, etc. The paper discusses how fatigue sensitivity analysis was carried out on different structural components of two wheeled vehicles like chassis, engine link, mounting accessories, welded components, etc. It also describes how the methodology was useful in pinpointing causes of the likely failure, in arriving at simple but very effective modifications, etc.

Various techniques have been developed for vehicle durability test in laboratory by using dedicated, sophisticated simulation software, specially developed rigs and vehicle holding fixtures. Such setups are expensive and complex. A successful attempt was made to devise a simple, effective, economical, accelerated technique for fatigue evaluation of two wheeler on two poster, using simple vehicle holding fixture, dead weights and low end software for drive file generation. Paper discusses the methodology adopted for road load data acquisition, analysis and simulation in laboratory. To judge the quality of simulation, comparison was made between acquired data in field (target data) and response data on rig from various angles. The exercise enabled to generate quick drive file and compress the test span by about 25 times than the actual road test. The technique was very much useful for quick evaluation of chassis, body components, plastic panels etc. during developmental stages.