Lightweight Design of Suspension Balance-Axle Bracket Based on Nonlinear Strength Simulation and Experiment

In order to cope with market changes, a certain commercial vehicle platform balance suspension system urgently needs to be lightweight to reduce costs. The suspension system is faced with a series of contact nonlinear problems of complex structures. The structure obtained by traditional simplified design and simulation methods often breaks in the test verification, which is much different from the expectation. Therefore, according to the contact numerical algorithm of the software, this paper considers the nonlinear characteristics of suspension strength in modeling, conducts electrical test and simulation benchmarking with the production process of actual cold assembly of the factory, and finally summarizes the adjustment methods of various parameters and convergence characteristics of contact nonlinear analysis, and forms a set of nonlinear strength simulation analysis methods suitable for suspension systems. This method laid an important foundation for the subsequent lightweight design work, and the lightweight balanced suspension system after multiple rounds of simulation optimization successfully passed the bench and vehicle reliability tests, and the lightweight suspension was successfully put on the market and obtained great economic value.