G scholar, mechanical engineering, ips college of technology management 2 hod, mechanical engineering, ips college of technology management, gwalior mp india email. Leaf springs are used in heavy load vehicle where load is much larger than in passenger vehicles, they are used in vehicles which are limited to varying cycles stress to millions thus eventually leads to failure of fatigue. According to the studies, a material with maximum strength and minimum modulus of elasticity in the longitudinal direction is the most suitable material for a leaf spring. Explore design, analysis, fabrication and testing of a composite leaf spring with free download of seminar report and ppt in pdf and doc format. Design analysis and fabrication of composite mono leaf.
Leaf spring design and engineering strength of materials. Analysis of parabolic leaf spring failure date 29 april 2011 pagesappendices 45 supervisors mr. Pdf design, analysis and optimization of leaf spring. Design of leaf springs mechanical engineering notes edurev. The dimensions of an existing conventional steel leaf spring of a light commercial vehicle are taken and are verified by design calculations.
Design analysis and fabrication of composite mono leaf spring for automobile vehicle k. Design and analysis of leaf spring by using composite materials. As shown in the picture, the leaf spring or laminated leaf spring consists of a couple of fulllength leaf and a number of graduated leaves. Paszek performed a three dimensional contact analysis of the car leaf spring. Multileaf spring this type of leaf spring has more than 1 leaf in its assembly. Satyanarayan, static and dynamic analysis on composite leaf spring in heavy vehicle, international journal of advanced engineering research and studies,vol. Pdf leaf springs design, calculation and testing requirements. Tension spring design becomes a much easier task when it comes to designing your tension springs at acxess spring. Static and fatigue analysis of multi leaf spring used in the. Design and analysis of eglassepoxy composite monoleaf. This paper presents detailed finite element modeling and analysis of a twostage multileaf spring, a leaf spring assembly, and a hotchkiss suspension using abaqus.
It is seen that the maximum bending stress is about 450. It has been experimentally tested for deflection, stress and load rate on a full scale leaf spring testing machine. Static and fatigue analysis of multi leaf spring used in. Dynamic analysis of leaf spring using ansys amitkumar magdum post graduate student, vit university, vellore, india. It was found that the longitudinal orientations of fibers in the laminate offered good strength to the leaf spring.
Nipping in leaf spring the stress in the full length leaves is 50% greater than the stress in the graduated leaves. So half area of leaf spring with eye is created 15. The dimensions of an existing conventional steel leaf spring of a light commercial vehicle are taken and are verified. The main point of the analysis study is to improve the quality of this design for a leaf spring with a longer life, and achieve a big reduction in vibration forces. They considered static three dimensional contact problem of the leaf car spring and the solution is obtained by finite element method performed in adina 7.
The objective is to compare the stresses, deformations and weight saving of composite leaf spring with that of steel leaf spring. Stiffness, composite leaf spring, eglassepoxy, ansys 12. Design and analysis of composite leaf spring by using fea and. Stock plates will not accept our largerdiameter ubolts. The experimental fatigue life prediction of leaf springs is a time consuming process. The suspension leaf spring is one of the potential items for weight reduction in automobile 4. For this purpose, a rear leaf spring for mahindra modelcommander 650 di is considered. Once the spring life limit is reached a fatigue failure will or has occurred. In fact they are made blunt or even made straight to increase the load bearing capacity. Introduction leaf springs are mainly used in suspension systems to absorb shock loads in automobiles like light motor vehicles, heavy duty.
The present paper deals with the design and analysis of composite leaf spring. Based on this, small reduced model is developed to make different iterations to design, cost effective rear axle with minimum time. He simply piled one steel plate on top of another, pinned them together and shackled each end to a carriage, it was the first ever leaf spring used on a vehicle. Design and analysis of leaf spring by using composite. Position of the leaf spring during braking modelling and analysis in engineering the stress and strain concentration at any point has. Invention of leaf spring leaf spring was invented by obadiah elliot of london in 18th century.
The steel leaf spring was replaced with an optimized composite one. As per the static analysis on 8leafs we can concluded that eglass epoxy is better. Analysis of leaf spring the deflection using the 3d finite and the composite leaf spring is set to analyze the static element strength. A 3 d model of entire leaf spring is modeled using solid works. Stresses and strains under different loads were analyzed. A leaf spring is a simple form of spring, commonly used for the suspension wheeled vehicles. Deflection of master leaf steel by analyzing the design, it was found that all the. Composite materials are one of the material families which are attracting researchers and being solutions of. Numerical simulation of leaf spring a finite element structural analysis of the front and rear leaf spring models under the y direction load. From the basic equations of bending stress and deflection, the maximum stress. The analysis has been conducted by using ansys12 software with the help of static structural tool. The leaf spring was modeled in autocad 2012 and the analysis was done using ansys 9.
So this fixed eye end of the leaf spring cannot move in. Composite leaf springs were analyzed for tensile properties, loaddeflection behavior, strain rate sensitivity, hysteresis behavior damping, and relaxation. A leaf spring is a simple type of suspension spring commonly used in heavy duty vehicles. The leaf spring is astructural member and acts as an energy absorbing system on the virtue of its deflection. Design and analysis of leaf spring for solar vehicle proceedings of 105th ththe iier international conference, bangkok, thailand, 5 6th june 2017 105 table 4 shows the result data of front leaf spring iii. Use of leafspring plates lsp01 or lsp02 is recommended. In the cantilever beam type leaf spring, for the same leaf thickness, h, leaf of uniform width, b case 1 and, leaf of width, which is uniformly reducing from b case 2 is considered. From the results of static analysis of steel leaf spring, it is seen the displacement of leaf spring is 53. Design analysis and fabrication of composite mono leaf spring. Sowjanya, design and analysis of automotive multi leaf spring using composite material. Design and analysis of composite leaf spring for light weight vehicle.
This condition may be obtained in the following two ways. The basic principles of leaf spring design and assembly. Reducing weight while increasing or maintaining strength of products is getting to be highly important research issue in this modern world. Static structural cae analysis of symmetrical 65si7 leaf. With the theory of leaf spring and by hypermesh software following result for structure analysis result is concluded. Typical semielliptical leaf spring is shown in figure 18. Originally called a laminated or carriage spring, and sometimes referred to as a semielliptical spring, elliptical spring, or cart spring, it is one of the oldest forms of springing, appearing on carriages in england after 1750 and from there migrating to france and germany. A 65si7 light commercial vehicle leaf spring is chosen for this study. Analysis and optimization of a composite leaf spring. Design and analysis of a leaf spring for automobile. So, a stress analysis was performed using finite element method. In order to utilise the material to the best advantage, all the leaves should be equally stressed.
Design, analysis, fabrication and testing of a composite. Design, analysis, fabrication and testing of a composite leaf. A leaf spring is a long, flat, thin and flexible piece of spring steel or composite material that resists bending. The suspension leaf spring is one of the potential. The objective also aims to compare the stresses, deformations and weight saving of composite leaf spring with that of conventional steel leaf spring, where stiffness is the design constraint. He simply piled one steel plate on top of another, pinned them together and shackled each end to a carriage, it.
Nonlinearity from large deformation, interleaf contact, and friction was included. Use of leaf spring plates lsp01 or lsp02 is recommended. A practical model of leaf spring used in lcv has been taken into consideration for this study. A threelayer composite leaf spring with full length leave made of eglassepoxy composite material has been used. Leaf spring bushings total control leaf spring, polyurethanebushing sets provide a more stable interface between the leaf springs and the chassis. The objective also aims to compare the stresses, deformations and weight saving of composite leaf spring with that of conventional. In new light commercial vehicle development, engine is mounted at rear to have low engine noise and vibration inside cabin. Evaluation of a leaf spring failure continued submitted july 18, 2005. Camber is the perpendicular distance between the reference line and the master leaf and its magnitude is such that the spring is approximately straight under the max static load. Leaf spring design guidelines laminated leaf spring. A finite element approach for analysis of multi leaf spring using cae tools research journal of recent sciencesvol 1,292,96feb 2012. G scholar, mechanical engineering, ips college of technology management. The design process of the leaf spring is another aspect that can be optimized in order to improve the load carrying capacity and fatigue life of the spring. The work presented in this paper provides alternate methods for fatigue life assessment of leaf springs.
Static and dynamic analysis of automobile leaf spring tata ace. For the leaf spring analysis one of the eye ends of the leaf spring is fixed to the chassis of the vehicle. Static and dynamic analysis of automobile leaf spring. The experimental results verified the analytical and the finite element solutions. Proceedings of 105th the iier international conference, bangkok, thailand, 5th6th june 2017 102 design and analysis of leaf spring for solar vehicle 1may mya darli cho, 2htay htay win, 3aung ko latt 1,2,3 department of mechanical engineering, mandalay technological university, mandalay, myanmar email. The suspension system in a vehicle significantly affects the behavior of vehicle, i. The leaf spring which is taken as model has the advantages of loading symmetry in geometry. Frp springs also have excellent fatigue resistance and durability. A leaf spring is a simple form of spring commonly used for the suspension in wheeled vehicles.
Solid model of a leaf spring created in creo software. Since fixed support has restriction to move in x and y direction as well as rotation about that fixed point. The effect of the orientation of fibers is studied. Experimental investigation of composite leaf spring reinforced with. Initially analysis is done with complete vehicle model of rear axle, spring, spring bushes, frame etc. Abstracta leaf spring is the simplest type of suspension system, widely used in heavy commercial vehicles. No parameter value 1 gross vehicle weight 2150 kg 2 wheelbaseb 2680 mm 3 max speed 90 kmhr 4 engine mdi3000.
This project describes design and experimental analysis of composite leaf spring made of glass fiber reinforced polymer. The engineers working in the field of leaf springs always face a challenge to formulate alternate methods of fatigue life assessment. At the same time there is a need of high load carrying rear suspension to suit market requirement. Join the above two key points to get reference axis to rotate the right side line of areal extrude the line with respect to reference axis to an angle 2750 to 2800. Design and analysis of composite leaf spring by using fea. Kevlarepoxy for light commercial vehicle leaf spring. International journal of engineering trends and technology. Leaf springs also known as flat spring are made out of flat plates. For this purpose, a rear leaf spring for mahindra bolero is considered.
Leafspring bushings total control leafspring, polyurethanebushing sets provide a more stable interface between the leaf springs and the chassis. This paper presents detailed finite element modeling and analysis of a twostage multi leaf spring, a leaf spring assembly, and a hotchkiss suspension using abaqus. Analysis of steel and composite leaf spring international journal. Design and analysis of composite leaf spring international journal of mechanical and industrial engineering ijmie, issn no. It consists of a center bolt that properly aligns the leaves and clips to resist its individual leaves from twisting and shifting. You can also observe from the picture of the leaf spring that the thickness of the whole spring is maximum at the centre and is gradually decreases towards the ends. A steel leaf spring used in the rear suspension of light passenger cars was analyzed by two analytical and finite element methods. A file in pdf format which provides technical information regarding a certain tension spring design. Student, in mechanical design engineering department, r. First the static analysis is carried out for steel and different composite leaf spring using fe solver ansys v10. Keywords leaf spring, composites, catia, ansys, suspension system.
Static structural analyses of the both conventional and tapered leaf springs are carried out. Finite element analysis is done to predict the behavior of both the steel and composite leaf springs. Design and analysis of leaf spring global journals inc. The component chosen for analysis is a leaf spring which is an automotive component used to absorb vibrations induced during the motion of vehicle. Regardless of how well a spring is maintained or how favorable the operating conditions are, all springs will eventually fail from fatigue caused by the repeated flexing of the spring. Information in table 2 is not sufficient to design a composite leaf spring. The analytical calculation was carried out for conventional leaf spring. Tension spring design pdf quality spring, affordable prices. We provide you with our newly remodeled spring calculator, spring creator v3. In this paper we describe design and analysis of composite leaf spring. Design and analysis of a laminated composite leaf spring.
Design, analysis and optimization of leaf spring open. Leaf spring failure analysis springs are a limited life component. All the calculations were done using the version 5. Leaf spring modeling niklas philipson modelon ab ideon science park se22370 lund, sweden niklas. In the present work, a nineleaf steel spring used in heavy vehicle. Also explore the seminar topics paper on design, analysis, fabrication and testing of a composite leaf spring with abstract or synopsis, documentation on advantages and disadvantages, base paper presentation slides for ieee final year mechanical. The suspension of leaf spring is the area which needs to focus to improve the suspensions of the vehicle for comfort ride.