Abstract
Leaf springs constitute the most effective suspension way of commercial vehicle axles from the cost and maintainability point of view. Especially in case of front axles, they overtake both the guidance and suspension functions, which consequently designates them as safety components, whose pre-mature failure is explicitly prohibited. The present paper deals with the fatigue performance of downsized parabolic leaf specimens made of the high-strength spring steel 51CrV4 under serial manufacturing conditions. It focuses on the influence of the major manufacturing steps, i.e. the heat treatment and the subsequently applied stress shot peening. The effectiveness of the applied heat treatment on the microstructure transformation and the extent of surface decarburization is determined by means of optical microscopy and corresponding microstructural analyses. Comprehensive series of constant amplitude fatigue tests are executed before and after the applied stress shot peening to quantify its effectiveness on the fatigue performance. The tests cover two characteristic stress ratios of operational significance with the complete range of interest being experimentally investigated. Additionally, surface residual stresses measurements together with micro- and macro-hardness and roughness values before and after stress shot peening are executed to expose the influence of each individual technological effect on the overall fatigue performance.
Highlights
Leaf spring-based suspension systems dominate the commercial vehicle sector since they constitute a cost-effective and maintenance-free solution for both suspending and guiding front and rear axles
The present paper is devoted to the quantitative determination of the effects of these heat and surface treatments implemented during the serial production of high-performance parabolic leaf springs, as well as their contribution to the utter fatigue life of downsized specimens under constant amplitude loading for distinctive, operational-relevant stress ratios
A thorough and comprehensive study of the fatigue life of leaf specimens has been carried out covering all major production stages, i.e. the Heat Treated and Tapered (HTT), serial steps lead to the final product (SSP) and double SSP conditions
Summary
Leaf spring-based suspension systems dominate the commercial vehicle sector since they constitute a cost-effective and maintenance-free solution for both suspending and guiding front and rear axles. Https://doi.org/10.10 51/matecconf /202134904007 components to regulate the axle travel during operation, they are considered to be safetycritical elements, whose pre-mature or uncontrolled failure should be either completely avoided or properly handled Even though their design and form seems fundamental and simplistic, their detailed layout and manufacturing requires high precision and closely-controlled processes, calibrated for such components. The present paper is devoted to the quantitative determination of the effects of these heat and surface treatments implemented during the serial production of high-performance parabolic leaf springs, as well as their contribution to the utter fatigue life of downsized specimens under constant amplitude loading for distinctive, operational-relevant stress ratios. In order to achieve legitimate transferability to the final product, yet significantly decrease the testing time and costs of the experimental investigations, downsized leaf spring specimens were designed and manufactured according to the serial production procedures and protocols. The above assessment is supported by and supplemented with macro- and micro-hardness measurements in conjunction with roughness properties that offer an overall evaluation of the surfaces’ competence and durability performance
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