Abstract
The experimental fatigue life prediction of leaf springs is a time consuming process. The engineers working in the field of leaf springs always face a challenge to formulate alternate methods of fatigue life assessment. The work presented in this paper provides alternate methods for fatigue life assessment of leaf springs. A 65Si7 light commercial vehicle leaf spring is chosen for this study. The experimental fatigue life and load rate are determined on a full scale leaf spring testing machine. Four alternate methods of fatigue life assessment have been depicted. Firstly by SAE spring design manual approach the fatigue test stroke is established and by the intersection of maximum and initial stress the fatigue life is predicted. The second method constitutes a graphical method based on modified Goodman's criteria. In the third method codes are written in FORTRAN for fatigue life assessment based on analytical technique. The fourth method consists of computer aided engineering tools. The CAD model of the leaf spring has been prepared in solid works and analyzed using ANSYS. Using CAE tools, ideal type of contact and meshing elements have been proposed. The method which provides fatigue life closer to experimental value and consumes less time is suggested.
Highlights
In actual practice, the load rate and fatigue life are determined experimentally
The leaf spring is mounted in the machines simulating the condition of the vehicle, the fatigue test stroke is determined, and the leaf spring is tested from maximum stress to minimum or initial stress
As the experiments are done on a full scale leaf spring testing machine under the specified loads, the CAE analysis has been carried out for the same loads
Summary
The load rate and fatigue life (under specified stress range) are determined experimentally. For the assessment of experimental fatigue life, a full scale leaf spring testing machine is required. The analytical or simulation techniques provide an approximate fatigue life, the validation of these results through experimental testing is mandatory. Refngah et al [2] worked on the possibility and capability of replacing the multileaf with the parabolic spring in suspension system. He performed the finite element analysis to analyze the stress distribution and behavior of both the springs. Time histories service loading data was analyzed and damage area was simulated to predict the fatigue life of the components. Fuentes et al [3] studied the origin of premature failure analysis procedures, including examining the leaf spring
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