Light Weight Suspension Coil Springs by Advanced Manufacturing Techniques and Innovative Design Definition Methods

Paper #:
  • 2010-01-1143

Published:
  • 2010-04-12
Citation:
Neubrand, J., Lindner, A., Brandt, R., and Junker, C., "Light Weight Suspension Coil Springs by Advanced Manufacturing Techniques and Innovative Design Definition Methods," SAE Technical Paper 2010-01-1143, 2010, https://doi.org/10.4271/2010-01-1143.
Pages:
9
Abstract:
For more than 20 years Mubea strives to develop and produce highly stressed suspension springs and other lightweight automotive steel products. Despite continuous increase of load stress levels of suspension springs it was possible to significantly reduce the weight of suspension springs while increasing robustness.As a successful supplier the company needs to address the continually increasing requirements of the automotive industry for reduced vehicle weight and CO₂ emission through strong efforts in design and process optimization. Targeted now is a weight reduction of another 10% while further enhancing coil spring robustness. In order to achieve these targets Mubea has again optimized the already established High Performance Process (HPP) and has developed a new and innovative method of designing coil springs.To optimize coil spring design customized Finite Element (FE) software was developed and successfully implemented. This allows for appropriate distributing of working stresses along the coil spring profile. The objective is to achieve both, maximum weight reduction and maximum robustness, respectively. Suspension springs featuring this optimized spring design are described as "New Generation" coil springs. Mubea Coiling Programming System (MCPS) in combination with the Spring Setup Indicator (SSI) - a 3D measurement system for coil springs - allows for efficient and highly process capable rapid prototyping and mass production setup of "New Generation" coil springs.Using the example of the Mubea Side Load (SL) suspension spring for McPherson strut applications the HPP process technology and the formerly introduced spring design concept "New Generation" will be explained and discussed.
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