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This paper presented one calculation method of the contact load, which is the load acted on the spring at the moment when the second-level stiffness of the spring just begins to work. In the proposed method, the contact load calculation mainly based on the dynamic load of the unsprung mass and the road grades and the commonly driving speed were also considered. A semiempirical formula of the contact load was put forward. Then the contact load of the commercial bus's rear suspension was respectively calculated by using the proposed formula and traditional methods(geometric mean method and average load method) to compare each other and to verify the new method. Later, the spring samples were respectively manufactured based on the calculation results. At last, the validation tests were respectively performed in an automotive proving ground.

Aiming at the difficulty of sovling the stiffness calculation of taper-leaf spring with variable stiffness, a combined method was proposed, which combine superposition method and finite difference method. Then the calculation results of different differential segments were compared with experimental results. The compared results show that the proposed method is effective and simple. So it has some practical significance in designing the taper-leaf spring. In addition, based on the stiffness test of the taper-leaf spring, the proper adjustments to the correction factor of the single parabolic leaf spring stiffness formula was recommended(ξ =0.92-0.96).