Research on the structural performance and fatigue life analysis of commercial vehicle stabilizer bars

The stabilizer bar is a crucial component of the car suspension, and its fatigue failure can significantly compromise the safety of driving. To verify whether the stabilizer bar meets the target fatigue life. This paper initially constructs a finite element model of the lateral stabilizer bar, computes the maximum Mises stress at critical sections, and formulates the stress at these points using mechanical principles. The theoretical results validate the effectiveness of the finite element model. Subsequently, the lateral stiffness of the stabilizer bar is calculated, and its accuracy under vertical load is validated using stiffness bench tests. Based on this, the rain flow matrix for one test cycle within the mixed segment of the test site is converted into a single-amplitude sine wave with a constant frequency using the equal damage method. Subsequently, bench fatigue tests and fatigue simulation analyses were conducted separately to determine the test and simulation lifespans under sinusoidal loads. The accuracy of fatigue simulation analysis was verified by comparing the test and simulation life. Random loads from road tests were utilized as input for the fatigue simulation, predicting the fatigue life of the stabilizer bar. This paper employs a combination of fatigue finite element analysis and fatigue testing to predict the fatigue life of stabilizer bars. This fatigue prediction scheme that combines finite element analysis and experimentation can be extended to other component systems, thereby shortening the development cycle of new products.