Failure analysis and structural optimization of a commercial vehicle leaf spring
To solve the issue of steel leaf spring fracture in a commercial vehicle,the spring failure is analyzed from various aspects,such as leaf spring material,forming process,and structural design strength,and a nonlinear simulation model for leaf springs is built considering the load characteristics of different working conditions.According to the loading standard of the entire vehicle impact condition,the stress of the leaf spring under each condition is extracted.A detailed model of the leaf spring assembly is built,and the reliability of plate springs and bridge shell bottom plates is computed using the extracted leaf spring stress as the load,so the weak parts and the cause of fracture is determined.Taking the thickness of the main spring as the design variable,the structural stress of the leaf spring as the constraint condition,and the minimum total mass as the constraint objective,the size optimization of the leaf spring is carried out to find the minimum thickness of the spring that meets the stress requirements.The optimized main and auxiliary springs are subjected to fatigue durability tests,and the accuracy of the simulation results is verified.
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