Comprehensive Endego support in optimizing component durability.

Project challenge: structural strength – assessment and optimization

The Client approached Endego with a specific request: to analyze the strength and durability of multiple structural and mechanical components of pickup trucks under real-world operating conditions. The key focus areas included:

• main frame with cargo box,
• cover and roof of the cargo box,
• roof rack,
• test frame,
• bolted connections.

Each of these components had to withstand vibrations and dynamic driving loads, like accelerations. Additionally, where the strength criteria were not met, Endego task was to optimize the design and to improve the static and dynamic performance while providing manufacturability on a high level.

Our approach: advanced engineering simulations & FE analyses

To meet the Client’s expectations, the Endego Virtual Validation team applied Finite Element analyses to evaluate and optimize the pickup truck’s structural components.

Key steps in the analysis:

1. Creation of detailed FE Models:
   • each component was modeled individually, including its material properties, loading conditions, and interaction with other parts.
   • the bolted connections were precisely depicted to capture their real behavior under dynamic road conditions.
2. Static strength and vibration dynamics calculations:
   • static load cases were defined to determine stress distribution and deformation under typical operational loads.
   • vibration behavior was analyzed, with natural frequencies in focus and their Effective Mass Participation (EMP) to predict high energy resonance ranges.
3. Optimization of structural properties:
   • collaboration with the Customer’s team enabled Endego to refine bolted connections, stiffness distribution, and dynamic performance features.
   • the optimization process had reduced stress concentrations in focus while providing high technological feasibility.

By leveraging expertise in CAE-driven design, Endego ensured that all components meet strength and durability standards and requirements, and exhibit reduced failure risk, and avoid costly redesign.

Project outcome: reliable and light weight pickup components

The parts and assemblies designed and optimized by Endego engineers exceed industry requirements and were validated for long-term reliability. The key benefits for the Client included:

• safe and failure-free operation of lightweight pickup truck components for years to come,
• significant expansion of production capacity for these components,
• enhanced cooperation with leading automotive OEMs, thanks to high product reliability.

Endego’s expertise in strength and reliability with tolls like FE analyses and CAE optimization has helped the Client to appear as a more confident and attractive partner within the automotive industry.

Partner with Endego for advanced engineering solutions with CAE tools

At Endego, we specialize in simulation-driven product development, helping automotive manufacturers enhance product durability, optimize design performance under minimum weight, and streamline production efficiency.

If your company is looking for engineering expertise in structural analysis, vibration optimization, and bolted and welded connection assessment, reach out to us today! Endego team of experts is ready to support your next automotive, rail, or industrial project with its best CAE solutions.

📩 Contact us to discuss your Engineering Challenges