The purpose of this study is to develop an acceleration-strain conversion model that considers torsional strain and spring curvature effects in inducing strain for a suspension coil spring. Measurements of strain–time histories at the coil spring are limited by complex geometry and insufficient workspace. This condition increases the demand for strain signal generation through multibody dynamics (MBD) simulation, reducing the need for real strain measurement of coil spring. Road tests were conducted to obtain the unsprung mass acceleration and strain signals of a coil spring under four road conditions (rural, industrial, highway, and campus road). Quarter-car suspension MBD simulation was modelled to simulate the deflection of a spring excited under unsprung mass acceleration. By using this model, simulated strain data with similar properties as the experimental data were generated for fatigue life prediction. The predicted fatigue life from the generated strain indicated a good correlation with the experimental fatigue life within the boundary and showed very low normalised root-mean-square error (NRMSE) between 4 × 10⁻⁶ and 2 × 10⁻⁴. Finally, it is suggested that the acceleration-strain conversion model showed an enhanced performance for producing realistic strain signals in accurately predicting the durability of coil spring. This can, therefore, further reduce the need for real strain measurement at the coil spring that can result in an erroneous signal.

这项研究的目的是建立一个加速度-应变转换模型，该模型考虑了扭力和弹簧曲率在悬架螺旋弹簧感应应变中的影响。螺旋弹簧应变时间历史的测量结果受复杂的几何形状和工作空间不足的限制。这种情况增加了通过多体动力学（MBD）仿真生成应变信号的需求，从而减少了对螺旋弹簧实际应变测量的需求。进行了道路测试，以获取在四种道路条件（农村，工业，公路和校园道路）下螺旋弹簧的簧下质量加速度和应变信号。对四分之一汽车悬架MBD仿真进行了建模，以模拟在未悬挂质量加速度的情况下激发的弹簧的挠度。通过使用此模型，具有与实验数据相似的特性的模拟应变数据可用于预测疲劳寿命。由产生的应变预测的疲劳寿命表明与边界内的实验疲劳寿命具有良好的相关性，并且在4×10之间显示出非常低的归一化均方根误差（NRMSE）^-6和2×10 ^-4。最后，建议加速度-应变转换模型在准确预测螺旋弹簧的耐久性方面表现出增强的性能，可以产生真实的应变信号。因此，这可以进一步减少在螺旋弹簧上进行实际应变测量的需要，因为这可能会导致信号错误。