This paper highlights the fatigue life prediction and interactions between weld design parameters and their effect on doubler plate weld joint by using the virtual strain gauging validated through experimental testing and also applied to off-highway vehicles welded components. The finite element analysis was applied on doubler plate weld joint to understand the effect of weld geometry parameters, load condition and constraint. In order to evaluate the Fatigue Life (Lf), the statistical technique known as Response Surface Method was used with the help of three weld joint parameters, Plate thickness (Pt), Prep Angle (Pa) and Load (Ld) on Fatigue life (Lf). Prep angle shows to have an effect on fatigue life only up to 45 degree while fatigue life is detrimental at 48 degree and 60 degree prep angle, whereas the load increases, the fatigue life decreases. The experimental results show that the presence of a secondary bending affects the experimental values of fatigue life. Virtual strain gauging methodology has been applied to off-highway vehicle machine dynamic event of the machine and to fatigue life successfully. © 2018 Praise Worthy Prize S.r.l.-All rights reserved