In this paper, dynamic loads acting on a twin-tube hydraulic shock absorber are derived out both in wheel and axle planes by modeling mechanically car rear suspensions, and internal and external forces that yield lateral surface damage and wear-out of the piston rod for the absorber are analyzed according to bench and real road test measures. From viewpoint of vehicle system dynamics and experiment, such key factors as road unevenness, very high car speed and severe shock induced vibrations are investigated, by which stochastic bending moments and dramatically increasing shock loading are introduced directly to the piston rod. From viewpoint of the whole car assembly, on the other hand, due to hardly perfectly placements of the piston rods in their positions between the car suspension and body, unacceptable manufacturing quality of the body may cause additional dynamic forces on the piston rod. Significant results obtained by theoretical and experimental analysis of lateral frictions of the piston rod are presented systematically for improving design of the shock absorber.
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