Study on Fatigue Bench Load Spectrum of Leaf Spring with Variable Section
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摘要: 钢板弹簧台架疲劳载荷谱一般来源于经验估算值，不能准确反映钢板弹簧真实工况承载状态。本文提出一种新的钢板弹簧台架疲劳载荷谱编辑方法，从整车实际工况出发，综合应用道路载荷谱采集、多体动力学建模和载荷谱编辑技术，基于钢板弹簧试验场原始随机载荷谱编辑出台架疲劳载荷谱。采用仿真分析与试验验证两种技术手段，对比分析钢板弹簧试验场原始随机载荷谱与台架疲劳载荷谱对构件的影响规律，结果表明，两种谱下的钢板弹簧失效方式一致，台架谱较原始谱更为保守，证明可以通过载荷编辑技术实现钢板弹簧疲劳性能分析从昂贵的试验场验证转换到简单高效的室内台架验证。Abstract: The leaf spring bench fatigue load spectrum has always been derived from the empirical estimates. It does not reflect the true stress state of the leaf spring. A new method for editing the leaf spring bench fatigue load spectrum is proposed. Starting from the actual working conditions of the vehicle, road load spectrum acquisition, multi-body dynamics modeling, and load spectrum editing techniques were comprehensively applied. The bench load spectrum was edited based on the original random load spectrum of test field. The simulation analysis and experimental verification were used to compare the effects of the original random load spectrum and bench load spectrum on the component. The results show that the leaf spring failure modes under the two spectrum are the same, and the bench spectrum is more conservative than the original spectrum. It proves that the fatigue analysis of leaf spring can be transformed from the expensive test field verification to simple and efficient indoor bench verification by using the load editing technology.
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Key words:
- leaf spring /
- bench load spectrum /
- multi-body dynamics /
- fatigue damage
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表 1 传感器选配说明
通道统计 传感器名称 测量参数 单位 32 轮心六分力 纵向力 N 侧向力 N 垂向力 N 倾翻力矩 Nm 制动力矩 Nm 回正力矩 Nm 轮心加速度 g 车速 km/h 30 加速度 轴头加速度 g 车架加速度 4 位移 前、后弹簧位移 mm 29 应变花 车架应变 με 4 GPS 行驶轨迹 − 1 触发器 路段标定 − 
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表 2 钢板弹簧强度工况分析结果
序号 工况 加速度/g 板簧与车桥连接点载荷(左) ax ay az Fx/N Fy/N Fz/N Tx/（Nm） Ty/（Nm） Tz/（Nm） 1 上跳冲击 – – −2 574 −138 17388 −50 −80 112 2 转弯 – −0.8 −1 2109 5790 13240 −610 290 −650 3 制动 0.8 – −1 5190 −46 4750 −31 −2070 410
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表 3 钢板弹簧疲劳试验台架谱
疲劳工况类型 力 力矩 加载频率/Hz 方向 幅值/N 循环次数 方向 幅值/（Nm） 循环次数 垂向 垂向 17388 49688 – – – 1 侧倾 垂向 13240 86332 绕垂向 650 428559 1 制动 垂向 4750 670788 绕侧向 2070 47203 1
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表 4 钢板弹簧刚度试验值与仿真值对比
负荷/N 挠度/mm 相对误差/% 试验值 仿真值 0 0 0 – 4500 67.4 67.2 0.3 7500 107.7 108.3 0.56 12000 140.5 140.3 0.14 13500 158.2 160.2 1.26
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表 5 0方向线应变仿真值与试验值标定结果
测点编号 垂向工况 制动工况 试验值/με 仿真值/με 误差/% 试验值/με 仿真值/με 误差/% 1 2268 2370 4.5 355 342 3.7 2 3620 3220 11 705 786 11.5 3 3623 3450 4.8 1786 1806 1.1 4 2720 2444 10.1 998 1052 5.4
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表 6 侧倾工况主应变仿真值与试验值对比
测点编号 试验应变/με 仿真应变/με 误差/% 1 1286 1504 17 2 2408 2476 2.8 3 2369 2796 18 4 1699 1777 4.6
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