Fatigue Life Assessment of Automotive Leaf Springs

Abstract

Abstract The creation of a new mechanical component, such as a high-performance leaf spring, is a very challenging procedure that consists of many stages over a long timeframe from concept to production. High performance leaf springs are components with high complexity at the areas of failure. This complexity is derived from the multiple manufacturing processes that the raw material undergoes to reach its final geometrical and microstructural form. The paper shows the assessment of fatigue life of high-performance leaf springs, from different manufacturers with different geometrical and loading parameters. The assessment uses the fatigue life calculations which are described at the FKM Guideline as a basis. Limitations of the FKM Guideline, concerning the material’s ultimate tensile strength and the exclusion of the stress shot peening process, are restricting the fatigue life calculations of such components, therefore, a new theoretical tool is needed for more accurate calculations.