During the field tests of a prototype of a cabin suspension assembly applied in a commercial vehicle it has been evidenced the premature failure in the torsion bar. Due to this failure, which happened with 20% of approval total test, one verified that the adding of a lateral displacement control bar (Panhard), attached to the torsion bar, promoted a significant additional force to it, which was not predicted in the initial dimensioning.
Due to that, it was executed a re-design of the assembly, paying a special attention to the torsion bar, considering the influence of Panhard bar. To do that, several numerical simulations were carried out, using the finite element software Abaqus, whose boundary conditions were determined based on data collected in the field tests. Lately, the new concepts developed were submitted to bench tests, applying hydraulic actuators to apply the loads, in which one executed an experimental verification of stresses to calibrate the numerical models.