Reyansh Kukreja
Independent Researcher
India
Abstract
This manuscript investigates the fatigue behavior of automotive suspension components subjected to variable load conditions representative of real‐world driving. The study focuses on leaf springs and control arms fabricated from conventional high‐strength spring steels and aluminum alloys as prevalent materials in 2015. Employing established fatigue analysis techniques—such as the Goodman relation, S–N curve assessment, and Miner’s rule—the research quantifies component life under block‐loading profiles derived from standardized road spectra. Two case studies illustrate field data application: a rural roadway and an urban pothole sequence. Results highlight significant life reduction when load amplitude sequences deviate from constant‐amplitude assumptions. Research gaps in multiaxial stress characterization and material microstructure influence are identified. The methodology integrates laboratory fatigue testing, finite element stress analysis (pre–2015 codes), and cumulative damage modelling. Findings indicate that control arm fatigue life can decrease by up to 40% under realistic variable loading, while leaf springs exhibit 25% reduction. Conclusions recommend design safety factors adjusted for load sequence sensitivity and call for advanced multiaxial fatigue studies.
KeyWords
fatigue analysis, variable loading, automotive suspension, block loading, cumulative damage, finite element analysis, Goodman relation, miner’s rule, S–N curve, leaf spring, control arm
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