Abstract: In order to solve the crack failure of spring tray of front suspension for a pickup in test rig fatigue test, firstly the FE model of damper spring tray was built, the stress history of tray was simulated in spring motion process between jounce and rebound, the fatigue life of tray was analyzed by applying Miner Counting Algorithm for acuminated fatigue analysis, and the failure was accurately reproduced. With the enlargement of tray chamfer, the tray has passed test rig experiment and also full vehicle road durability test, which has shown the engineering practicability of this methodology. This has a good guiding significance to the structure design of shock absorber.

Key words: Pickup front suspension; Failure of spring tray; Fatigue analysis; Computer aidedengineering (CAE); Shock absorber structure optimization

摘要： 为解决某皮卡前弹簧减震器总成台架疲劳试验中弹簧托盘的开裂失效问题，首先用有 限元技术建立弹簧减震器托盘模型，模拟得到弹簧减震器在拉升、压缩工作过程中托盘应力， 然后运用 Miner 线性累加损伤方法对托盘进行疲劳分析，实现故障再现。通过增大托盘冲压 型面倒圆角，使其通过了台架试验及整车道路耐久试验，表明了此方法的工程有效性。该方 法对减震器结构设计具有很好的指导意义。

关键词: 皮卡前悬架；弹簧托盘开裂；疲劳分析；计算机辅助工程（CAE）；减震器结构优化