商用车复合材料板簧设计分析

李芸先¹，李伟^1*，陆浩宇²，王强¹，周帅¹

1.山东交通学院汽车工程学院，山东 济南  250357；2.青岛特锐德电气股份有限公司，山东 青岛  266104

摘要：在满足轻型货车整备质量限值要求的前提下，为降低轻型货车板簧质量，采用玻璃纤维-环氧树脂复合材料替代传统钢材，对板簧进行轻量化设计与分析。采用三维建模软件Creo构建复合材料板簧几何模型；基于设计刚度150.0(1±5%) N/mm的要求，通过有限元仿真确定纤维铺层厚度比，并分析板簧在静态垂向、制动和转弯工况下的强度；结合台架试验对模压工艺制备的复合材料样件进行验证。结果表明：对比原板簧，采用纤维方向与样件长度方向夹角为0°、45°的玻璃纤维-环氧树脂复合材料，铺层比例为6:5时，板簧质量由26 kg降为10 kg，板簧质量降低61.5%；板簧仿真刚度为153.1 N/mm，台架试验测试板簧实际刚度为155.0 N/mm，均处于设计刚度允许偏差范围内；该复合材料板簧各工况下的安全因数均大于1.20，且台架疲劳寿命达到30万次未失效，满足使用要求。

关键词：轻量化；复合材料板簧；设计仿真；台架试验

Design and analysis of composite leaf springs for a commercial vehicle

LI Yunxian¹, LI Wei^1*, LU Haoyu², WANG Qiang¹, ZHOU Shuai¹

1.School of Automotive Engineering, Shandong Jiaotong University, Jinan 250357, China;

2.Qingdao TGOOD Electric Co., Ltd., Qingdao 266104, China

Abstract: To reduce the mass of leaf springs for light trucks while meeting the curb weight limit requirements, glass fiber-epoxy resin composites are used to replace conventional steel for lightweight design and analysis of leaf springs. A geometric model of the composite leaf spring is established using the 3D modeling software Creo. According to the design stiffness requirement of 150.0(1±5%) N/mm, the fiber layup ratio is determined through finite element simulation, and the strength of the leaf spring under static vertical, braking, and cornering conditions is analyzed. Bench tests are carried out to verify the composite samples fabricated by compression molding. The results show that comparing with the original steel leaf spring, when the layup ratio of composite materials with fiber angles of 0° and 45° relative to the sample length direction is 6:5, the leaf spring mass is reduced from 26 kg to 10 kg, representing a mass reduction of 61.5%. The simulated stiffness of the leaf spring is 153.1 N/mm, and the measured actual stiffness from bench test is 155.0 N/mm, both within the allowable deviation range of the design stiffness. The safety factors of the composite leaf spring under all working conditions are greater than 1.20, and the fatigue life in bench test reaches 300 000 cycles without failure, which meets the application requirements.

Keywords: lightweight design; composite leaf spring; design and simulation; bench test