The Method of Synthesis of the Geometry of the Longitudinal Profile and the Design Parameters of the Leaf Spring Using the Finite Element Method

BACKGROUND: In most cargo vehicles, leaf springs are used as an elastic element in the suspension, therefore, improving approaches to the calculation and synthesis of vehicle suspensions with leaf springs to reduce vibration load and to increase ride comfort is a relevant issue. Using the synthesis of the longitudinal profile of the spring leaves of complex shape, it is possible to achieve high strength properties of a leaf spring with a sufficiently low stiffness by applying calculations and optimizations using the finite element method (FEM), which helps to create a more perfect spring shape in terms of ride smoothness of the vehicle. AIM: Development of a new method for the synthesis of a leaf spring with a variable profile of its longitudinal section and obtaining its characteristics using modern engineering methods based on the use of the FEM. METHODS: The solution of the task is carried out in the NX software package including the Simcenter 3D CAE software. Topological optimization is applied to obtain the geometry of the longitudinal profile of the leaf spring, and then a strength test calculation is performed using the FEM to obtain the characteristics of the leaf spring. RESULTS: During the work carried out at the KAMAZ Innovation Center, a method for forming the longitudinal profile of a leaf spring (regardless of the number of leaves) was developed and the dependences of the stiffness of the leaf spring on its parameters were constructed. According to the obtained dependencies, the optimal geometry of the longitudinal profile of the spring was synthesized, in which the stiffness was reduced by 33% compared to the prototype of the spring, while maintaining the bearing capacity of the vehicle. CONCLUSION: This method of synthesis of the geometry of the longitudinal profile and the design parameters of the leaf spring can be used in the design processes of vehicle suspensions and to be further applied during research work.