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Leaf spring experiences frequent cyclic loading during working conditions. When design stage itself it is very essential to assess the fatigue life of the suspension system. It is important to consider and evaluate the key aspects of fatigue failure and life by using Finite Element Analysis (FEA) techniques to overcome these failures. This paper serves to stimulate the premature failure of the existing and proposed bracket model with generalized force elements under dynamic load conditions. Scanning Electron Microscope (SEM) was used to identify the bracket failure prone areas which indicate that the cyclic load in the suspension system is caused by rural area road-induced vibrations and bumps. This contributes to the increase of the fatigue fracture, which ends up with a bracket failure. The results indicated that the fatigue life of existing bracket is low for rough road conditions; the modified bracket has been optimized for the safe load conditions of the heavy vehicle suspension system

Fatigue life prediction of heavy vehicle suspension system under varying load conditions