Semitrailer chassis design against fatigue on the basis of field test data

During the previous HVTT conference in Melbourne, results have been presented of a project FORWARD, including eleven different trailer manufacturers, involving testing and modeling activities to establish a practical basis for realistic fatigue assessment as a step towards an improved light-weight trailer design. The present paper describes the next step as part of the follow-up project LIFE (LIfetime Fatique Enhancement), starting with the model-based assessment of a realistic loading history for a semi-trailer. Representative loading conditions in this history, being derived from three weeks of field testing, are then used in Finite Element analyses to estimate fatigue life at a critical high loaded welded connection in the aluminum trailer chassis. Results are discussed with respect to the order of different loading cycles (Palmgren-Miner number, based on fatigue tests), 3D loading at the weld, the varying weld quality, and the impact of bonded connections in the trailer. These ‘lessons learned’ are interpreted, to result in improved general guidelines in light-weight trailer design.