REVEALING THE DYNAMICS OF LEAF SPRINGS – CASE STUDY FAILURE MECHANISMS AND ADVANCING SUSPENSION SYSTEMS IN COMMERCIAL VEHICLES


Mohd Rosli Rasidi, Muhamad Zuraidi Rohani, Muhammad Abdullah

 Department of Mechanical Engineering, Polytechnic of Banting Selangor, Malaysia 



ABSTRACT

Leaf springs are critical in supporting vertical loads and isolating road-induced vibrations, making their fatigue life and reliability crucial for vehicle safety. This study investigates the dynamics and failure mechanisms of leaf springs in commercial vehicles, with a focus on the Mitsubishi Triton Quest 2.5L light truck. The experimental work included visual observations, a scanning electron microscope (SEM), hardness testing, and microstructural analysis. The study utilizes experimental methods to analyze the failure of the leaf spring, identifying corrosion and fatigue as the primary causes. Based on the observations of the fracture surface, it is revealed that the cause of failure was due to the cyclic load experienced by the components during operation, which caused crack propagation beginning with micro-cracks until reaching a significant dimension to cause a final fracture. The study concludes with recommendations to prevent similar failures, such as protective coatings, regular vehicle maintenance, and the use of high-quality materials. Overall, this research provides valuable insights into leaf spring failure analysis and the advancement of suspension systems in commercial vehicles.


Keywords:

Leaf Spring; ANSYS; corrosion; fatigue life;