Based on the experimental observations and simulation results,it can be concluded that an aggressively drilled open hole
created small crack initiations in a highs tress-state location of the frame,which resulted in extensive curvilinear crack
growth under dynamic loads of the vehicle.The FRANC 3D crack propagation tool combined with NASTRAN finite element
solver predicted crack path similar to physical test failure and provided a good correlation for cycles to failure.A sensitivity
study was done to identify safe zone for open holes and would help specify restrictions on frame hole drilling.The present
work provides successful methodology applied to failure analysis of frame rail cracks in heavy duty trucks,which may alsobe
applied for other engineering failure analysis problems