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In this paper, we describe the development of multi-axis, accelerated durability tests for commercial vehicle suspension systems. The objective of the exercise is to design accelerated durability tests that have well-defined correlation with customer usage. The procedure starts with a definition of the vehicle's duty cycle based on the expected operational parameters, namely: road profile, vehicle speed, and warranty life. The second step is determining the durability proving ground test schedule such that the accumulated pseudo-damage (based on spindle loads) is representative of the vehicle's duty cycle. The third step in the process is developing a multi-axis laboratory rig test for the suspension system, such that the accumulated damage in the proving ground is replicated in a compressed time frame.

Contact stress analysis or surface fatigue life prediction is a subject frequently encountered in powertrain component designs. Examples are the design of gears, bearings, cams, and load ramps. In many cases, design evaluations rely on simple analysis, component supplier's suggestions, and prototype testing. One viable technology trend in modern engineering, however, is to use computer simulation and analysis as a design guide. It is universally acknowledged that up-front computer-aided-engineering (CAE) will reduce the product development cycle time and cost, and improve product quality. In addition, this approach provides a good platform for technology growth. Scattered examples on surface durability analytical modeling techniques are available in the literature. But, the most suitable engineering tools for routine product design support are yet to be developed. Currently, a semi-empirical approach is widely used in the industry.