Abstract: In order to fulfill the matching design for the connection structures of the composite leaf spring in a light bus, the ultimate loads of the connection structures along different directions are obtained through multi-body dynamics simulation, and the parameter matching design method for the connection structure of composite leaf spring is proposed. According to the failure mode of connection structures, the design principle for the layup scheme of connection structure is proposed with the layup scheme optimized. Both fatigue bench test and real vehicle reliability test on the connection structures optimized are carried out. The results indicate that the designed connection structures of composite leaf spring can meet the requirements for installation on vehicles, having a great significance to ensure the reliability of composite leaf spring assembly and promote its popularization and application.

Key words: vehicle engineering, composite material, leaf spring, connection structure, lightweighting, bench test