Design and failure modes of automotive suspension springs
Design and failure modes of automotive suspension springs
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DOI：
10.1016/j.engfailanal.2007.11.003
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发表时间：
2008-12-01
影响因子：
4
通讯作者：
Nishikawa, A.
中科院分区：
文献类型：
--
作者：
Prawoto, Y.;Ikeda, M.;Nishikawa, A.
本文论述了汽车悬架螺旋弹簧的基本应力分布、材料特性、制造工艺及常见故障。并对影响螺旋弹簧质量的参数进行了深入探讨，顺应汽车行业不断实现轻量化的趋势，螺旋弹簧也不例外。减轻重量的努力的结果是，与几十年前的类似设计相比，需要使用应力明显更大的弹簧材料。使用更高强度的钢既有好处也有坏处。其优点包括可以在更高的应力水平和更复杂的应力下自由设计螺旋弹簧。使用压力水平较高的材料的缺点来自于压力本身。与在较低应力下使用螺旋弹簧相比，线圈不能正确执行其功能可能会造成更大的灾难。随着应力水平的增加，材料和制造质量变得更加关键。材料清洁度几十年前还不是一个主要问题，现在变得重要起来。过去不是主要问题的脱碳现在变得至关重要。为了确保螺旋弹簧满足其设计要求，对断裂的螺旋弹簧进行失效分析对于汽车制造商和零部件供应商的短期和长期议程都是有价值的。本文讨论了几个悬架弹簧故障的案例分析。出现的故障从最基本的承载能力不足、原材料缺陷(如夹杂物水平过高)和制造缺陷(如延迟淬火开裂)到由于复杂的应力使用和化学导致的故障。给出了典型破坏起始点周围应力分布的有限元分析结果。(C)2007爱思唯尔有限公司。保留所有权利。
This paper is a discussion about automotive suspension coil springs, their fundamental stress distribution, materials characteristic, manufacturing and common failures. An in depth discussion on the parameters influencing the quality of coil springs is also presented.Following the trend of the auto industry to continuously achieve weight reduction, coil springs are not exempt. A consequence of the weight reduction effort is the need to employ spring materials with significantly larger stresses compared to similar designs decades ago. Utilizing a higher strength of steel possesses both advantages and disadvantages. The advantages include the freedom to design coil springs at higher levels of stress and more complex stresses. Disadvantages of employing materials with higher levels of stress come from the stresses themselves. A coil's failure to perform its function properly can be more catastrophic than if the coil springs are used in lower stress. As the stress level is increased, material and manufacturing quality becomes more critical. Material cleanliness that was not a major issue decades ago now becomes significant. Decarburization that was not a major issue in the past now becomes essential.To assure that a coil spring serves its design, failure analysis of broken coil springs is valuable both for the short and long term agenda of car manufacturer and parts suppliers. This paper discusses several case studies of suspension spring failures. The failures presented range from the very basic including insufficient load carrying capacity, raw material defects such as excessive inclusion levels, and manufacturing defects such as delayed quench cracking, to failures due to complex stress usage and chemically induced failure. FEA of stress distributions around typical failure initiation sites are also presented. (C) 2007 Elsevier Ltd. All rights reserved.