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某商用车钢板弹簧失效分析与结构优化
Failure Analysis and Structural Optimization of a Commercial Vehicle leaf spring
2025-04-14 11:37
摘要：为解决某商用车钢板弹簧断裂问题，提出了结构件断裂失效分析方法，分别从板簧材质、成型工艺、结构设计强度多方面进行研究。考虑板簧不同工况场景的载荷特点，建立板簧仿真的非线性分析模型。根据整车冲击工况加载标准，通过多体载荷提取到整车冲击工况下板簧各工况的应力。再建立板簧总成的详细模型，将提取出来的载荷反施加至板簧，用以研究板簧及桥壳底板的可靠性，从而确定出板簧的薄弱部位与断裂的主因，同时为设计提供桥壳底板的指导意见。将主簧片作为设计变量，选取板簧的结构应力作为约束函数，板簧的总质量为约束目标，对板簧进行尺寸优化，通过该优化方法寻找到应力合格下的板簧最小厚度。依据法规对优化后的主副簧进行疲劳耐久试验，试验结果验证了仿真结果的准确性。总结板簧各工况下受力特点提供了一种用以仿真钢板弹簧非线性强度的加载验证方式，为同类板簧、桥壳底板的结构设计及零件断裂失效分析方法提供了借鉴。
Abstract: In order To solve the fracture problem of a commercial vehicle steel plate spring, a fracture failure analysis method for structural components was proposed, which was studied from various aspects such as plate spring material, forming process, and structural design strength. Establish a nonlinear analysis model for leaf spring simulation by considering the load characteristics of different operating scenarios of leaf springs. According to the loading standards for the entire vehicle impact condition, the stress of the leaf spring under various working conditions of the vehicle impact condition is extracted through multi body load. Establish a detailed model of the leaf spring assembly and apply the extracted load back to the leaf spring to study the reliability of the leaf spring and the bridge shell bottom plate, thereby determining the weak parts of the leaf spring and the main cause of fracture, and providing guidance for the design of the bridge shell bottom plate. Using the main spring as the design variable, selecting the structural stress of the leaf spring as the constraint function, and the total mass of the leaf spring as the constraint objective, the size of the leaf spring is optimized. Through this optimization method, the minimum thickness of the leaf spring under qualified stress is found. According to regulations, fatigue durability tests were conducted on the optimized main and auxiliary springs, and the test results verified the accuracy of the simulation results. Summarizing the force characteristics of leaf springs under various working conditions provides a loading verification method for simulating the nonlinear strength of leaf springs, which provides a reference for the structural design of similar leaf springs and bridge shell soleplates, as well as the analysis method for component fracture failure.
来源：数字仿真论坛
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