In the development of fabricated rear axle housing for heavy-duty off-road applications, engineering against failures was challenging due to budget and timeline limitations. Rear-axle housing failure on the road is a threat to other road users and hence zero failures targeted in the design verification phase. The analysis of rear axle housing beam failures had been well established. Failure in Torture-Track (TT) was resolved by engineering against the stress concentration at the notch, by adding inner side weld at the central section of the axle. This optimized design got verified in FEA and Rig testing for maximum stress concentration reduction and fatigue life improvement, respectively. The optimized design completed the target mileage in TT successfully. Further strengthening of the central section resulted in the failure mode shift from the central section to the beam section (proved in Rig testing). Hence, reestimated the life of rear-axles based on new strain measurement in severe operation. The strain measurement data from off-road testing of the design prototype closer to real-world application gave more accurate stress concentration results. It became the critical influencer to reduce further design iterations based on failures observed during design verifications in the new product development process.

在开发用于重型越野应用的后桥壳体时，由于预算和时间限制，针对故障进行的工程设计具有挑战性。道路上的后桥房屋故障对其他道路使用者构成威胁，因此在设计验证阶段将零故障定为目标。对后桥外壳梁故障的分析已得到充分确定。通过在轴中心部分增加内侧焊缝，通过克服缺口处的应力集中，可以解决折痕（TT）的故障。这种优化的设计在FEA和Rig测试中得到了验证，分别可以最大程度地降低应力集中和改善疲劳寿命。优化的设计成功完成了TT中的目标里程。中央部分的进一步加固导致失效模式从中央部分转移到梁部分（在钻机测试中得到证明）。因此，在严酷操作中，根据新的应变测量值重新估算了后桥的使用寿命。来自设计原型的越野测试的应变测量数据更接近实际应用，从而给出了更准确的应力集中结果。根据在新产品开发过程中设计验证期间发现的故障，减少进一步的设计迭代成为了关键的影响因素。来自设计原型的越野测试的应变测量数据更接近实际应用，从而给出了更准确的应力集中结果。基于在新产品开发过程中的设计验证中观察到的故障，减少进一步的设计迭代成为了至关重要的影响因素。来自设计原型的越野测试的应变测量数据更接近实际应用，从而给出了更准确的应力集中结果。根据在新产品开发过程中设计验证期间发现的故障，减少进一步的设计迭代成为了至关重要的影响因素。