Simulation and Design of Leaf Spring Characteristics

A nonlinear leaf spring FEA simulation technique is developed. An explicit nonlinear FEA code which considers large deflection and inter-leaf contacts has been used in the simulation. The basic characteristics of leaf springs, stress, stiffness and inter-leaf slipage, can be accurately calculated. Two different kinds of leaf springs which are variable stiffness leaf spring and tapered leaf spring have been studied using the FEA technology. Simulation results correlate well to test data. Based on the FEA simulations, relationships between the stress distribution rule and other factors, i.e., length and thickness, have been summarized. Rules of stress determination between leafs are established. Also, the relationship between the change of stiffness and the slippage between leafs caused by different forms of arcs of leaf spring was investigated.