Lightweight design of vehicle components based on strengthening effects of low‐amplitude loads below fatigue limit

A new lightweight design method for vehicle components is proposed based on the strengthening effects of low‐amplitude loads below the fatigue limit. The new method is technically based on the strength feature of strengthening and damaging of vehicle components under loading spectrum, while combining dynamic strength equations with the residual strength of vehicle components. It ensures the maximum exploitation of the material's strength potential and fully realises the lightweight design of vehicle components at a low cost. As an application of the new lightweight design method, a light truck's front axle was redesigned. The lightweight potential of the front axle was first estimated by fatigue and static strength experiments of four‐point bending. Then the lightweight design was realised by finite element analysis and experimental results. The weight of this front axle was reduced by 5.5 kg.