The bolted joints in suspension systems are subjected to severe external service loads during vehicle operation. To prevent the loaded joint from loosening and allowing it to retain its potential energy stored during assembly, a holistic design approach is needed. This paper explains the methodology to design and optimize bolted joints for the suspension systems of a modern 7-seater sports utility vehicle. The optimization technique consists of - Based on the results, joinery design approaches are discussed which focus on increasing the resistance against slip and utilizing the optimum preload applied during assembly. For critical joints experiencing high service loads, the torque to yield (torque plus angle) method is prescribed instead of the elastic tightening method along with reduction of the axial gap. For double shear joints having steel sleeve and sheet metal interface, improvements seen with the addition of serrations/knurling on the contact surface of the sleeve are discussed. The stiffness of mating parts is increased for proper bolt load transfer. With the incorporation of these design modifications in the joinery, extensive vehicle durability tests are performed in the vehicle, and no incidences of joinery loosening/slipping are observed. The efficacy of the design improvement was reflected in the residual torque values which showed no reduction after the test compared to the start of the test.
A Comprehensive Methodology to Design and Develop Suspension System Bolted Joints using Vehicle Test Loads and CAE Simulation
Sae Technical Papers
WCX SAE World Congress Experience ; 2023
2023-04-11
Conference paper
English
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