This paper introduced two methods of automotive suspension springs stress analysis, the FEA （finite element analysis） and the experimental measurement, through which the maximum stress is found located where the cyl...This paper introduced two methods of automotive suspension springs stress analysis, the FEA （finite element analysis） and the experimental measurement, through which the maximum stress is found located where the cylinder number is the integer multiple of the first half cycle from the spring end. By scattering or removing the maximum stress points, optimum design, which is based on the cosmosworks method, will promote the fatigue reliability and the employ life of the springs.展开更多
The fatigue life and reliability of wrought carbon steel castings produced with an optimized mold design are predicted using a finite element method integrated with reliability calculations.The optimization of the mol...The fatigue life and reliability of wrought carbon steel castings produced with an optimized mold design are predicted using a finite element method integrated with reliability calculations.The optimization of the mold is carried out using MAGMASoft mainly based on porosity reduction as a response.After validating the initial mold design with experimental data,a spring flap,a common component of an automotive suspension system is designed and optimized followed by fatigue life prediction based on simulation using Fe-safe.By taking into consideration the variation in both stress and strength,the stress-strength model is used to predict the reliability of the component under fatigue loading.Under typical loading conditions of 70 kN,the analysis showed that 95%of the steel spring flaps achieve infinite life.However,under maximum loading conditions of 90 kN,reliability declined significantly,with only 65%of the spring flaps expected to withstand the stress without failure.The study also identified a safe load-induced stress of 95 MPa on the spring flap.The findings suggest that transitioning from forged to cast spring flaps is a promising option,particularly if further improvements in casting design reduce porosity to negligible levels,potentially achieving 100%reliability under typical loading conditions.This integrated approach of mold optimization coupled with reliability estimation under realistic service loading conditions offers significant potential for the casting industry to produce robust,cost-effective products.展开更多
A new type of linear rotary magnetorheological damper (MRD) is proposed, which consists of a cylinder-type MRD and a screw mechanism to transform a linear motion into revolving motion. It is found that the structure p...A new type of linear rotary magnetorheological damper (MRD) is proposed, which consists of a cylinder-type MRD and a screw mechanism to transform a linear motion into revolving motion. It is found that the structure parameters of MRD have complex relationship with the force of the damper, especially the lead angle, width and radius of the inner rotor. The analyses and simulation calculation of the static magnetic field give some usable data, and experiments of the damping component indicate that the proposed methods is feasible for developing linear rotary MRD.展开更多
文摘This paper introduced two methods of automotive suspension springs stress analysis, the FEA （finite element analysis） and the experimental measurement, through which the maximum stress is found located where the cylinder number is the integer multiple of the first half cycle from the spring end. By scattering or removing the maximum stress points, optimum design, which is based on the cosmosworks method, will promote the fatigue reliability and the employ life of the springs.
基金funded by Interdisciplinary Research Center for Intelligent Manufacturing and Robotics at King Fahd University of Petroleum and Minerals (KFUPM),Dhahran,through Project#INMR2107.
文摘The fatigue life and reliability of wrought carbon steel castings produced with an optimized mold design are predicted using a finite element method integrated with reliability calculations.The optimization of the mold is carried out using MAGMASoft mainly based on porosity reduction as a response.After validating the initial mold design with experimental data,a spring flap,a common component of an automotive suspension system is designed and optimized followed by fatigue life prediction based on simulation using Fe-safe.By taking into consideration the variation in both stress and strength,the stress-strength model is used to predict the reliability of the component under fatigue loading.Under typical loading conditions of 70 kN,the analysis showed that 95%of the steel spring flaps achieve infinite life.However,under maximum loading conditions of 90 kN,reliability declined significantly,with only 65%of the spring flaps expected to withstand the stress without failure.The study also identified a safe load-induced stress of 95 MPa on the spring flap.The findings suggest that transitioning from forged to cast spring flaps is a promising option,particularly if further improvements in casting design reduce porosity to negligible levels,potentially achieving 100%reliability under typical loading conditions.This integrated approach of mold optimization coupled with reliability estimation under realistic service loading conditions offers significant potential for the casting industry to produce robust,cost-effective products.
文摘A new type of linear rotary magnetorheological damper (MRD) is proposed, which consists of a cylinder-type MRD and a screw mechanism to transform a linear motion into revolving motion. It is found that the structure parameters of MRD have complex relationship with the force of the damper, especially the lead angle, width and radius of the inner rotor. The analyses and simulation calculation of the static magnetic field give some usable data, and experiments of the damping component indicate that the proposed methods is feasible for developing linear rotary MRD.
