BACKGROUND: In most cargo vehicles, leaf springs are used as an elastic element in the springing system, therefore, improving approaches to the calculation and synthesis of car spring suspensions to reduce vibration load and increase driving comfort is an urgent issue. Thanks to the synthesis of the longitudinal profile of the spring sheets of complex shape, it is possible to achieve high spring strength properties with a sufficiently low stiffness by applying calculations and optimizations using the finite element method (FEM), which allows you to create a more perfect spring shape in terms of smoothness of the vehicle.
AIMS: Creation of a new technique for the synthesis of a leaf spring with a variable profile of its longitudinal section and obtaining its characteristics using modern design methods based on the use of FEM.
MATERIALS AND METHODS: The solution of the task is carried out in the NX software package in the Simcenter 3D strength calculation environment. To obtain the geometry of the longitudinal profile of the leaf spring, topological optimization is applied, and then a strength test calculation is performed using FEM to obtain the characteristics of the leaf spring.
RESULTS: During the work carried out at the KAMAZ Innovation Center, a method for forming the longitudinal profile of a leaf spring (regardless of the number of sheets) was developed and the dependences of the stiffness of the leaf spring on its parameters were constructed. According to the obtained dependencies, the optimal geometry of the longitudinal profile of the spring was synthesized, in which the stiffness was reduced by 33% compared to the prototype of the spring, while maintaining the bearing capacity of the vehicle.
CONCLUSIONS: This technique of synthesis of the geometry of the longitudinal profile and the design parameters of the leaf spring can be used in the design processes of vehicle springing systems and further applied during research work.