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Enhancement of fatigue life of multi-leaf spring by parameter optimization using RSM

  • Vinkel Kumar AroraEmail author
  • Gian Bhushan
  • M. L. Aggarwal
Technical Paper

Abstract

The experimental investigation to predict the effect of mechanical processing, strength reduction factors, design, geometric tolerances and material factors on the fatigue life of a leaf spring is costly and time-consuming process. A computer program based on the analytical approach has been developed in FORTRAN, for determination of the fatigue life of a leaf spring of a light commercial vehicle. It takes into account the effect of five factors namely overall strength reduction factor (processing), stiffness (design), span and width (geometry) and ultimate tensile strength (material) on the fatigue life of the leaf spring. The results of the program have been validated experimentally using a full-scale leaf spring testing machine. A mathematical model has also been developed using response surface methodology. The optimal sets of parameters yielding the maximum fatigue life are obtained using the desirability approach. The confirmatory experiments are carried out and the results indicate that the developed model is appropriate for determination of fatigue life within 5 % variation. The interaction effects of the factors affecting fatigue life have also been studied and the overall strength reduction factor is found to be the most significant one.

Keywords

Leaf spring Fatigue life Design factor Geometry factor Strength reduction factor Material factor 

Nomenclature

Ca

No load assembly camber

E

Young’s modulus of elasticity

Nf

No. of cycles to failure

Nfp

Predicted fatigue life

ρ

Density

µ

Poisson’s ratio

Sa

Alternating stress

σmax

Maximum stress

Se

Endurance limit

Se

Corrected endurance limit

Sy

Yield tensile strength

L

Span

σmin

Minimum stress

Sm

Mean Stress

Sae

Equivalent alternating stress

Sut

Ultimate tensile strength

Ksurface

Surface factor

Kload

Load factor

Ktemp

Temperature factor

Ksize

Size factor

Kreliability

Reliability factor

Sm

Stress at 103 cycles

Notes

Acknowledgments

The authors would like to acknowledge Mr. P S Chawla and the leaf springs testing division of Friends Auto (India) Ltd, whose unconditional support have made this project successful.

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Copyright information

© The Brazilian Society of Mechanical Sciences and Engineering 2016

Authors and Affiliations

  • Vinkel Kumar Arora
    • 1
    Email author
  • Gian Bhushan
    • 2
  • M. L. Aggarwal
    • 3
  1. 1.Department of EngineeringNIFTEM, HSIIDCKundliIndia
  2. 2.Department of Mechanical EngineeringNational Institute of TechnologyKurukshetraIndia
  3. 3.Department of Mechanical EngineeringYMCA University of Science and TechnologyFaridabadIndia

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