Parametric Design Study of McPherson Strut to Stabilizer Bar Link Bracket Weld Fatigue Using Design for Six Sigma and Taguchi Approach

Vehicle suspension parts are subjected to variable road loads, manufacturing process variation and high installation loads in assembly process. Seam welding can be considered as such process to connect more components and parts. Typical in a Mc Pherson suspension system stabilizer bar link is connected to the strut assembly through ball stud and clamped to a bracket welded to the outer strut tube.

Cracks have been observed in the stabilizer bar link bracket welds of vehicles in the field, effecting the functionality of the suspension system. During preliminary phase of product development CAE assessment of the seam weld is carried out against road load data, if the design does not meet the targets enabler studies are carried out in an iterative approach. Various design variables (control factors) can be considered to carry out the iterations.

Design for Six Sigma (DFSS) and Taguchi approach are used to carry out a parametric design study of the weld attachment to quantify the effect of various control factors over fatigue life. This can quantify the relation and weight factor of each control factor or variables effecting the fatigue life. A study performed using Taguchi approach can provide an optimized design solution which can provide better fatigue life performance against higher road loads.