Application and Validation of CAE Methods for Comprehensive Durability Assessment of Leaf Springs with Measurement and Testing

Securing the desired strength and durability characteristics of suspension components is one of the most important topics in the development of commercial vehicles because these components undergo multiaxial variable amplitude loading. Leaf springs are essential for the suspension systems of trucks and they are considered as security relevant components in the product development phase. In order to guide the engineers in the design and testing department, a simulation method is developed as explained by Bakir et al. in a recently published SAE paper [1]. The main aim of the present study is to illustrate the validation of this simulation method for the durability of leaf springs based on the results from testing and measurements.

In order to verify this CAE Method, the calculated stresses on the leaf springs are compared with the results of strain gage measurements and the fatigue failures of leaf springs are correlated with the calculated damage values. In this study, the simulation results of different type of leaf springs in the front and rear axle truck suspension systems are presented together with the confirming results from testing and measurements. In this way, the validation of the CAE method is achieved with various testing applications.