مهندسی ساخت و تولید ایران

مهندسی ساخت و تولید ایران

بررسی تأثیر تغییر ضخامت لایه‌های دست فنر عقب کامیونت دایون سفارشی بر قابلیت اطمینان عمر دست فنر

نوع مقاله : مقاله پژوهشی

نویسندگان
1 دانشکده مهندسی مکانیک، دانشگاه صنعتی اراک، اراک، ایران
2 دانشکده مهندسی مکانیک، دانشگاه تربیت مدرس، تهران، ایران
10.22034/ijme.2025.532669.2099
چکیده
این مقاله بهینه‌سازی طراحی دست ‌فنر عقب کامیونت دایون را با رویکردی چندرشته‌ای و با تأکید بر بهبود همزمان عملکرد مکانیکی، قابلیت اطمینان و راحتی سرنشینان مورد بررسی قرار داده است. مقاله حاضر با ترکیب روش‌های تحلیلی، شبیه‌سازی‌های عددی و آزمون‌های تجربی به انجام رسیده است. در مرحله مدل‌سازی، طراحی پارامتریک دقیق با در نظر گرفتن تمامی جزئیات هندسی و مشخصات مواد فولاد آلیاژی 55Cr3 در محیط SolidWorks انجام شد. مدل ایجاد شده سپس به نرم‌افزار ANSYS منتقل شد و تحت تحلیل‌های المان محدود شامل شبیه‌سازی غیرخطی رفتار تماسی بین لایه‌ها، ارزیابی توزیع تنش تحت بارگذاری‌های ترکیبی و محاسبه عمر خستگی قرار گرفت. آزمون‌های تجربی شامل آزمونهای خستگی مطابق استاندارد ASTM و ارزیابی ضریب فنریت با دستگاه تست RANJBAR QCS98 انجام شد. تحلیل آماری داده‌ها در نرم‌افزار Minitab نشان داد که تغییرات اعمال‌شده در ضخامت، ضمن حفظ ضریب فنریت در محدوده مطلوب (انحراف معیار کمتر از 2 درصد)، منجر به بهبود 5/18 درصدی عمر خستگی و کاهش 3/12 درصدی تنش شده است. این بهبود در عملکرد، با افزایش ناچیز کمتر از 4 درصد در هزینه تولید همراه بوده که توجیه‌پذیری اقتصادی طراحی جدید را نشان می‌دهد.
کلیدواژه‌ها

عنوان مقاله English

Investigating the effect of changing the thickness of rear spring layers of a Custom-Made Dayun Truck on the life reliability of spring

نویسندگان English

Parvin Khosravi 1
Nima Hamta 1
Hamed Deilami Azodi 1 2
1 Department of Mechanical Engineering, Arak University of Technology, Arak, Iran
2 Department of Mechanical Engineering, Tarbiat Modares University, Tehran, Iran
چکیده English

This paper presents a multidisciplinary design optimization of the rear leaf spring for a Dayun truck, aiming to simultaneously enhance mechanical performance, reliability, and ride comfort. The research methodology integrates analytical calculations, advanced numerical simulations, and systematic experimental tests. A detailed parametric model, incorporating all geometric details and the material properties of 55Cr3 alloy steel, was developed in SolidWorks software. This model was subsequently imported into ANSYS software for comprehensive finite element analysis (FEA), including nonlinear contact simulation between layers, stress distribution assessment under combined loading, and fatigue life prediction. Experimental validation involved fatigue tests conducted in accordance with ASTM standards and spring rate evaluation using a RANJBAR QCS98 testing machine. Statistical analysis of the results in Minitab software demonstrated that the implemented thickness modifications, while maintaining the spring rate within the desired specification (standard deviation < 2%), yielded a significant 18.5% improvement in fatigue life and 12.3% reduction in maximum stress. These performance enhancements achieved with only a marginal production cost increase of less than 4%, confirming the economic viability and practical feasibility of the optimized design.

کلیدواژه‌ها English

Spring Optimization
Spring Design
Reliability
Dayun Truck
[1] Billinton R, Allen R, Rezaian M. Reliability assessment of engineering systems, concepts, and methods. Amirkabir University of Technology Publications, Tehran. 2014. [In Persian]
[2] Afshari SS, Enayatollahi F, Xu X, Liang X. Machine learning-based methods in structural reliability analysis: A review. Reliability Engineering & System Safety. 2022 Mar 1;219:108223. doi: 10.1016/j.ress.2021.108223
[3] Knight JC, Leveson NG. An experimental evaluation of the assumption of independence in multiversion programming. IEEE Transactions on software engineering. 1986 Jan 31(1):96-109. doi: 10.1109/TSE.1986.6312929
[4] Gholinezhad H, Torabi SH. Optimization of the reliability of a space probe's central computer using component lifespan data. Journal of Defense Readiness and Technology, affiliated with the Defense Readiness, Defense Technology, and Emerging Fields Research Institute of the Supreme National Defense University. 2021;4(4):11-32. [In Persian]
[5] Karbasizadeh M. Reliability assessment methods for multi-component systems: a comprehensive and practical review. Research in Production and Operations Management. 2023;14(2). [In Persian]
[6] Hu W, Cheng S, Yan J, Cheng J, Peng X, Cho H, Lee I. Reliability-based design optimization: a state-of-the-art review of its methodologies, applications, and challenges. Structural and Multidisciplinary Optimization. 2024 Sep;67(9):168. doi: 10.1007/s00158-024-03800-3
[7] Lee OS, Kim DH, Park YC. Reliability of structures by using probability and fatigue theories. Journal of Mechanical Science and Technology. 2008 Apr;22(4):672-82. doi: 10.1007/s12206-011-1232-1
[8] Behzad M, Ebrahimi A. Numerical and experimental fatigue life analysis of Volvo FH12 truck leaf spring. In: Proceedings of the 13th Annual (International) Conference on Mechanical Engineering (ISME2005); 2005 May 17-19; Isfahan, Iran. [In Persian]
[9] Pahnaneh F, Farhangi H, Farahmanesh K. Macro-fractography and analysis of failure causes in Volvo FM9 truck leaf springs. In: Proceedings of the 14th Iranian Student Conference on Materials Science and Metallurgy; 2017 Oct 11-12; Shahrekord, Iran. [In Persian]
[10] Jafari Bahramabadi M, Karimi Taheri A. Investigation of residual stress distribution and influencing factors in the manufacturing process of leaf springs using finite element modeling. In: Proceedings of the 5th National Conference on Metals and Materials Forming (MATFORM05); 2011 Oct 12; Tehran, Iran. [In Persian]
[11] Rahimi Ghazat M. Comparison of fatigue life in composite and metallic leaf springs [master's thesis]. Tehran: Sharif University of Technology; 2015. [In Persian]
[12] Barraza-Contreras JM, Piña-Monarrez MR, Molina A. Fatigue-life prediction of mechanical element by using the Weibull distribution. Applied Sciences. 2020 Sep 13;10(18):6384. doi: 10.3390/app10186384
[13] Hamzi NM, Singh S, Abdullah S, Rasani MR. Fatigue life assessment of vehicle coil spring using finite element analysis under random strain loads in time domain. International Journal of Structural Integrity. 2022 Jul 25;13(4):685-98. doi: 10.1108/IJSI-02-2022-0021
[14] Abdullah L, Karam Singh SS, Abdullah S, Ariffin AK, Zainal SS. Fatigue reliability characterisation of effective strain damage model using extreme value distribution for road load conditions. Materials. 2023 Jan 3;16(1):456. doi: 10.3390/ma16010456
[15] Manouchehry Nya R, Abdullah S, Singh SSK, Thamburaja P. Fatigue life prediction for automobile coil spring using modal analysis. International Journal of Engineering and Technology. 2018;7(3.17):260-5. doi: 10.14419/ijet.v7i3.17.21924
[16] Khedry H, Jamali G, Ghorbanpour A. Proposing a new dynamic maintenance model for reliability improvement by antifragility approach: A case study in Iranian Gas Transmission Company-Zone10. Journal of Gas Technology. 2021 Dec 1;6(2):65-82.
[17] Dehestani H. The effect of current intensity and feed rate on surface roughness and fatigue life of work piece in wire electrical discharge turning (WEDT) process. Iranian Journal of Manufacturing Engineering. 2020 Oct 22;7(8):36-44. doi: 10.1016/j.ijme.2020.08.005 [In Persian]
[18] Charkhi M, Akbari D. Evaluation and measurement of the residual stresses in stainless steel pipes and investigation of the effects of wall thickness on the stresses distribution. Iranian Journal of Manufacturing Engineering. 2018 Mar 11;4(2):61-8. [In Persian]
[19] Rafiee R, Bazargani S. Reliability Analysis of Failure in Composite Pressure Vessels. Iranian Journal of Manufacturing Engineering. 2021 Jun 22;8(4):50-61. doi: 10.1016/j.ijme.2021.04.004 [In Persian]
[20] Beer FP, Johnston ER, DeWolf JT, Mazurek DF, Sanghi S. Mechanics of materials. 8th ed. New York: McGraw-Hill Education; 2020.