Design, analysis and prototype manufacturing of maintenance free spherical joint bushing

This study focus on the design, analysis, and prototype manufacturing of maintenance-free spherical joint bushing that used in suspension of military vehicles. The aim is to overcome the problems of traditional production methods, such as torque control, friction uniformity and lining material accumulation, with a new design and manufacturing approach. TRIZ method was used in the design process, developing the concept of segmenting the bushing based on manufacturability and durability criteria. Additionally, four different designs were studied for the segmented bushing. Models created in SolidWorks software and analyzed using nonlinear static analyses in the Ansys software. Self-lubricating PTFE was preferred as liner material. In prototype production, the 30° angular cut design demonstrated the best performance. Static and dynamic tests confirmed that the 30° angular cut design reduces the liner wear and deformation, and providing a longer life than the straight-cut design. This method not only reduces maintenance costs but also offers a reliable solution for military vehicles operating under challenging conditions.