The aim of this study is to identify the issues that arise when measuring a strain signal in order to characterise fatigue failure. In traditional methods, acquisition of a strain signal is constrained due to the presence of errors, time-consuming process and associated high cost. In this study, a new method for generating strain signals based on computer simulation was proposed. A strain gauge was positioned near the citical area pertaining to an automotive coil spring driven on road surfaces in order to measure strain signals. The strain signals were utilised for the inputs in the simulation. For validation purposes, the actual and simulated strain signals were examined by performing fatigue tests. The actual and simulated urban strain signals, respectively, required 412 and 415 reversals of blocks. For the rural road, the fatigue life was 137 and 139 reversals of blocks, respectively, for the actual and simulated strain signals. These indicated that simulated strain signals were accurately generated, providing a minimum fatigue life deviation, which was lower than 1.5 %. By developing the strain signals of a component through simulation, its integrity and fatigue failure can adequately be determined, thereby, saving the cost associated with operation and maintenance. Thus, the simulation is expected to assist the automotive industries involved with strain signal acquisition.
Numerical analysis of the stress leading to fatigue failure on a coil spring of the front suspension of a car
