Structural optimization of ultra-thin leaf spring for weakening elastic hysteresis effect and enhancing fatigue life

Abstract

Small-size ultra-thin leaf spring as the key elastic sensitive member is widely used in the precision electro-mechanical products. However, owing to the unavoidable elastic hysteresis effect of leaf spring, it always suffers from a significant graceful degradation of designed deflection and subsequently fatigue fracture under the condition of cyclic loading. In order to weaken the elastic hysteresis effect, structural optimization according to sequential quadratic programming method for reducing stress concentration of leaf spring was first carried out by simulations, and then the identification of elastic hysteresis effect for optimal leaf spring was carried out by experiments. Compared with the original design, the maximum deflection deviation for single cycle is decreased from 0.026 mm to 0.002 mm. For the sake of predicting the fatigue life of optimal structure of leaf spring being on the service, a loading block with multistage variable stress amplitudes was experimentally recorded and fitted by normal probability density function, and then a statistical probability method by mathematical analysis was proposed. Compared with the original design, the predicted fatigue life of leaf spring is 736000 loading blocks, which is ten times than that before structural optimization. A structural optimization for reducing stress concentration can significantly weaken the elastic hysteresis effect and enhance the fatigue life, which is benefit for the elastic stability of leaf spring during engineering application.