Structural durability improvement of stabilizer bars under variable amplitude loading with heat treatment and tooling optimisation

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Structural durability improvement of stabilizer bars under variable amplitude loading with heat treatment and tooling optimisation

Morgenstern, C. / Kalinowski, B. / Ditzer, B. / Hieber, A.

Within this investigation different tubular stabilizer bars for a McPherson front strut suspension have been evaluated and optimised in terms of structural durability under constant and variable amplitude loadings. The stabilizer bars have to be validated in a complete front suspension assembly under customer service loads in multi-axis bench tests. By using different heat treatments these stabilizer bars have been optimised in order to increase the tensile strength and thus also their fatigue strength. In addition different production processes, as optimized bending and inner shot peening, have been applied to the bars and evaluated according to their effect on structural durability performance. In order to assess the success of these improvements, multi-axis bench and single axis constant amplitude tests at different load levels to determine the S-N curve and to investigate different fracture behaviour have been carried out. The achieved results have been compared with complete vehicle tests under variable amplitude loadings at bench and proving ground. Finally for all dimensions an optimized design which fulfils the required structural durability has been found.