某乘用车减振器弹簧座失效分析及结构优化

Failure analysis and structural optimization of the spring seat of a passenger car shock absorber

针对车辆前悬架减振器在强化路面实车测试中出现弹簧座局部断裂失效的问题,为进一步提高研发效率及实现极限设计,对某乘用车减振器弹簧座进行失效分析及结构参数优化。通过失效分析确定断裂与局部塑性变形有关,并对典型极限工况进行动力学分析,求解在有限元分析中所需的载荷;再对弹簧座模型进行弹塑性分析,确定塑性变形区主要为导程最高点弯折处;最后采用集成优化平台,对多个结构参数进行优化。结果表明,优化后模型未出现塑性变形,最大应力相比材料屈服应力少量富余10.13%,在强化路面实车验证中也未有失效发生,所提优化方法对类似工程问题具有实际应用价值。

To solve the problem of fracture of the spring seat of the front suspension shock absorber in the real vehicle test and improve the development efficiency and realize the limit design,failure analysis and structural parameter optimization were applied to the spring seat of a passenger car shock absorber.Through the failure mode analysis,it was determined that the fracture was related to the local plastic deformation,and the dynamic analysis of the typical limit working condition was carried out to solve the load required in the finite element analysis.Then the elastic-plastic analysis of the spring seat model was carried out to find that the plastic deformation area was mainly the highest point bending of the lead.Finally,the integrated optimization platform was used to optimize multiple structural parameters.The results show that there is no plastic deformation in the model after optimization,and the maximum stress is a small margin of 10.13%compared to the yield stress of the material,and there is no failure in the verification of the enhanced road surface.The proposed optimization method has practical application value for similar engineering problems.