The Structure Design And Fatigue Life Calculation Of The Few Leaf Spring

Nowdays, with the rapid development of automobile industry and increasing rise ofpeople life quality, the people have put forward higher requirements of the vehicle ridecomfort. In automobile suspension, leaf spring is one of the most widely applied elasticelements, when the road impact force coming, the leaf spring deforms to play a role of bufferand shock absorber. When longitudinal layout, it also has the guiding role, moreover,,it worksreliably with simple structure, low cost and convenient repair, so it is widely used onindependent suspension, but the traditional spring have larger weight, larger stiffness, poorcomfort. Therefore, it is importable to design a proper spring on vehicle.(1)Based on the few leaf spring structure design theory and the requirements of vehicle,fitting the up and down dimensions of the leaf spring to build the2D model. Then build the3D model in the software of UG..(2)Build the finite element mesh of the model in the Ansys panel with the software ofHypermesh. Simulate the non-linear contact behavior through adding contact elementbetween the two spring and spring, also between the spring and gasket. Then we apply thecorrect constraint, calculate the pre-stress in the process of clamp to guarantee the accuracy ofthe assembly. At last, we apply the real load on the model, calculate the stiffness, staticdeflection and dynamic deflection. According to the known parameters and the empiricalformula to calculate the limit load of few leaf spring, and calculate the stress applied with thelimit load, It can verify the reliability of few leaf spring.(3)Considering the fatigue load spectrum of the few leaf spring and then create the S-Ncurve of the material of the spring. Analyze the fatigue life of the few leaf spring with thesoftware of MSC.fatigue, so it can determine the risk area and the fatigue life of the few leafspring. At last, we complete the bench test of the few leaf spring and compare the results withthe results of the simulation, only in this way, can we guarantee the results by simulating.To design the few leaf spring with the CAE technology, It could find the exiting problemtimely before the product put into production which can help us do the further optimizationwork, to shorten the time of the product development, to reduce the cost, It is of greatsignificance for the batch production of products.