Fatigue Damage and Life Prediction of Rubber Structures in High‐Speed EMU Outer Windshields

ABSTRACT The rubber structure of high‐speed EMU outer windshields is subjected to multiple alternating loads during service, leading to frequent fatigue damage incidents that compromise operational safety, while long‐term tracking testing proves inherently challenging due to structural characteristics, presenting significant obstacles for fatigue damage research and life prediction. To address this, a finite element modeling method accounting for service mileage evolution is proposed, modal tests are conducted to validate model accuracy with 36 weak locations identified, and a rigid‐flexible coupled dynamics model incorporating windshield elasticity is established alongside a fatigue damage analysis methodology integrating curve vibration loads, straight‐line vibration loads, and aerodynamic loads. Furthermore, a fluid–structure interaction simulation model is constructed with bidirectional coupling between the windshield structure and airflow field considered, enabling analysis of surface and cross‐sectional pressure distributions for more realistic fatigue damage assessment under aerodynamic loads, thereby providing novel insights for predicting and evaluating the fatigue life of these rubber components.