Mechanical Analysis And Roll Forging Simulation Of Taper Leaf Spring

Leaf springs are elastic element which are one of the most widely applied in automobile suspension. The advantages of them are reliable operation, simple structure, convenient maintenance, low-cost and so on. But the disadvantages of traditional multi-leaf springs are heavy weight, high stiffness, long dimension, difficult to install and so on. And they do not conform to the requirements of lightweight of the modern vehicles, then the tape leaf springs appeared. Because of the uniform distribution of stress, compared to traditional leaf springs, they have better mechanical property and longer life. Meanwhile, the application of taper leaf spring is propitious to economical efficiency of vehicle, and improves riding comfort and security of vehicle. So the analysis and research of taper leaf spring has the great significance.In this paper, a model vehicle is used as a reference to determine the structure parameter, and study the mechanical property and simulation of roll-forging of taper leaf spring.Firstly, In the ABAQUS environment, Python language is used to write script program for modeling. At the same time, the tools of ABAQUS are used to create the human-computer interactive interface. In the dialog box, the parameters like dimensions of taper leaf spring, friction coefficient between two pieces and so on can be inputed. Using the script program can realize parameterized modeling quickly.Secondly, Based on ABAQUS, simulate the assembly process of taper leaf springs by considering the contact problem between two pieces of springs, and compare the value of simulation and selected, analyze the reason of producing errors. On the basis of the assembly, the loads are applied at the both ends of the main piece step by step to full load, and study the relationship between load and deformation, acquire the stiffness of simulation. Meanwhile, the distribution of stress can be obtained and study the influence of thickness to the distribution of stress. Then the periodicity of loads are applied the end of the taper leaf spring. We acquired hysteresis curve of taper leaf spring according to the relationship between load and displacement, and obtained the influence of amplitude, frequency, friction coefficient to hysteresis characteristics and equivalent damping.Finally, analyze the influence of process conditions to roll-forging by FE software, and utilize the method of prefroming width to create the forming model of taper leaf spring. Study the change of strain, contact area, rolling pressure, size, and analyze the thickness and width errors, show them eligibility and analyze the reason of producing width errors.This paper reveals the mechanical property and verify the reasonability of the design of taper leaf spring. Simulation of roll-forging the taper leaf spring can observe the process of forming directly and can be tested repeatedly. Simulation has great guiding significance to actual production.