Analysis of the Leaf Spring Failure in Light Duty Dump Truck

Abstract

This research analyzed the causes of failure in the leaf spring of a cold diesel Dump Truck. The test was conducted in the form of hardness using the Rockwell method and a hardness value of 104.8 HRB while microstructure analysis was used to view and identify fracture surfaces through SEM and optical microscope. Furthermore, the distribution of each spring load was determined by analytical analysis and found to be 28983 N while the chemical composition was analyzed by comparing the spring microstructure with the AISI 5150 standard. The finite element analysis conducted with the FEMAP software showed the maximum stress and strain values in the leaf spring were recorded on the left and right sides. The stress intensity factor (KI) around the end of the initial crack was also found to be greater than the fracture toughness of the material (KIC), thereby, causing the initiation and propagation of cracks in the leaf springs. It was, therefore, concluded that the failure in the spring was due to an initial defect caused by the dynamic load experienced by the spring, thereby, leading to the initiation and propagation of cracks up to the final fracture.