Solid model of a leaf spring created in creo software. Leaf spring failure analysis springs are a limited life component. Typical semielliptical leaf spring is shown in figure 18. In the finite element modeling, every leaf was modeled with eightnode 3d brick elements solid 45 and then fivenode 3d contact elements contact 49 were used to represent contact and. We provide you with our newly remodeled spring calculator, spring creator v3. G scholar, mechanical engineering, ips college of technology management. Kevlarepoxy for light commercial vehicle leaf spring.
This project describes design and experimental analysis of composite leaf spring made of glass fiber reinforced polymer. 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. Use of leafspring plates lsp01 or lsp02 is recommended. Design and analysis of composite leaf spring by using fea. Pdf design, analysis and optimization of leaf spring. Numerical simulation of leaf spring a finite element structural analysis of the front and rear leaf spring models under the y direction load. In fact they are made blunt or even made straight to increase the load bearing capacity.
Leafspring bushings total control leafspring, polyurethanebushing sets provide a more stable interface between the leaf springs and the chassis. Design, analysis, fabrication and testing of a composite leaf. Invention of leaf spring leaf spring was invented by obadiah elliot of london in 18th century. 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. Static and fatigue analysis of multi leaf spring used in.
Static structural analyses of the both conventional and tapered leaf springs are carried out. Composite leaf springs were analyzed for tensile properties, loaddeflection behavior, strain rate sensitivity, hysteresis behavior damping, and relaxation. He simply piled one steel plate on top of another, pinned them together and shackled each end to a carriage, it. 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. 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 analysis and fabrication of composite mono leaf spring. Analysis and optimization of a composite leaf spring.
Being able to capture the leaf spring characteristics is of signi. 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. The suspension leaf spring is one of the potential items for weight reduction in automobile 4. The dimensions of an existing conventional steel leaf spring of a light commercial vehicle are taken and are verified by design calculations. A leaf spring is a simple type of suspension spring commonly used in heavy duty vehicles. 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. Design and analysis of composite leaf spring by using fea and. Stiffness, composite leaf spring, eglassepoxy, ansys 12. The objective is to compare the stresses, deformations and weight saving of composite leaf spring with that of steel leaf spring. The experimental results verified the analytical and the finite element solutions. 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. Analysis of leaf spring the deflection using the 3d finite and the composite leaf spring is set to analyze the static element strength. The present paper deals with the design and analysis of composite leaf spring. The dimensions of an existing conventional steel leaf spring of a light commercial vehicle are taken and are verified.
Since fixed support has restriction to move in x and y direction as well as rotation about that fixed point. Design and analysis of leaf spring by using composite materials. A leaf spring is a simple form of spring, commonly used for the suspension wheeled vehicles. 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. For this purpose, a rear leaf spring for mahindra bolero is considered. Reducing weight while increasing or maintaining strength of products is getting to be highly important research issue in this modern world.
The basic principles of leaf spring design and assembly. As per the static analysis on 8leafs we can concluded that eglass epoxy is better. Satyanarayan, static and dynamic analysis on composite leaf spring in heavy vehicle, international journal of advanced engineering research and studies,vol. Initially analysis is done with complete vehicle model of rear axle, spring, spring bushes, frame etc. The effect of the orientation of fibers is studied. A leaf spring is a simple form of spring commonly used for the suspension in wheeled vehicles. A leaf spring is a long, flat, thin and flexible piece of spring steel or composite material that resists bending. In this paper we describe design and analysis of composite leaf spring. So this fixed eye end of the leaf spring cannot move in. The work presented in this paper provides alternate methods for fatigue life assessment of leaf springs. Information in table 2 is not sufficient to design a composite leaf spring.
Based on this, small reduced model is developed to make different iterations to design, cost effective rear axle with minimum time. Use of leaf spring plates lsp01 or lsp02 is recommended. In order to utilise the material to the best advantage, all the leaves should be equally stressed. 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 and analysis of leaf spring global journals inc. Static and dynamic analysis of automobile leaf spring.
Analysis of parabolic leaf spring failure date 29 april 2011 pagesappendices 45 supervisors mr. Feb, 2015 the suspension leaf spring is one of the potential items for weight reduction in automobile 4. The leaf spring was modeled in autocad 2012 and the analysis was done using ansys 9. Dynamic analysis of leaf spring using ansys amitkumar magdum post graduate student, vit university, vellore, india. In the present work, a nineleaf steel spring used in heavy vehicle. Student, in mechanical design engineering department, r. At the same time there is a need of high load carrying rear suspension to suit market requirement.
So half area of leaf spring with eye is created 15. First the static analysis is carried out for steel and different composite leaf spring using fe solver ansys v10. Static and fatigue analysis of multi leaf spring used in the. Design and analysis of leaf spring by using composite. With the theory of leaf spring and by hypermesh software following result for structure analysis result is concluded.
For the leaf spring analysis one of the eye ends of the leaf spring is fixed to the chassis of the vehicle. Leaf springs also known as flat spring are made out of flat plates. 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. This paper presents detailed finite element modeling and analysis of a twostage multileaf spring, a leaf spring assembly, and a hotchkiss suspension using abaqus. Position of the leaf spring during braking modelling and analysis in engineering the stress and strain concentration at any point has.
The engineers working in the field of leaf springs always face a challenge to formulate alternate methods of fatigue life assessment. Leaf spring design guidelines laminated leaf spring. The objective also aims to compare the stresses, deformations and weight saving of composite leaf spring with that of conventional. The leaf spring is astructural member and acts as an energy absorbing system on the virtue of its deflection. Multileaf spring this type of leaf spring has more than 1 leaf in its assembly. 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. All the calculations were done using the version 5. From the basic equations of bending stress and deflection, the maximum stress.
It has been experimentally tested for deflection, stress and load rate on a full scale leaf spring testing machine. Sowjanya, design and analysis of automotive multi leaf spring using composite material. 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. It consists of a center bolt that properly aligns the leaves and clips to resist its individual leaves from twisting and shifting. Stresses and strains under different loads were analyzed. It was found that the longitudinal orientations of fibers in the laminate offered good strength to the leaf spring.
Tension spring design pdf quality spring, affordable prices. Design and analysis of eglassepoxy composite monoleaf. A practical model of leaf spring used in lcv has been taken into consideration for this study. Design and analysis of composite leaf spring for light weight vehicle. 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. Design analysis and fabrication of composite mono leaf. The experimental fatigue life prediction of leaf springs is a time consuming process. A 65si7 light commercial vehicle leaf spring is chosen for this study. Design and analysis of a laminated composite leaf spring. The steel leaf spring was replaced with an optimized composite one. 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.
Design and analysis of a leaf spring for automobile. Evaluation of a leaf spring failure continued submitted july 18, 2005. Analysis of steel and composite leaf spring international journal. Experimental investigation of composite leaf spring reinforced with. 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. Paszek performed a three dimensional contact analysis of the car leaf spring. Design of leaf springs mechanical engineering notes edurev. Once the spring life limit is reached a fatigue failure will or has occurred. Design, analysis and optimization of leaf spring open. Leaf spring modeling niklas philipson modelon ab ideon science park se22370 lund, sweden niklas. Abstracta leaf spring is the simplest type of suspension system, widely used in heavy commercial vehicles. A 3 d model of entire leaf spring is modeled using solid works. Multileaf spring and hotchkiss suspension cae simulation.
From the results of static analysis of steel leaf spring, it is seen the displacement of leaf spring is 53. Composite materials are one of the material families which are attracting researchers and being solutions of. 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. Leaf spring design and engineering strength of materials.
Introduction leaf springs are mainly used in suspension systems to absorb shock loads in automobiles like light motor vehicles, heavy duty. Frp springs also have excellent fatigue resistance and durability. Leaf spring bushings total control leaf spring, polyurethanebushing sets provide a more stable interface between the leaf springs and the chassis. G scholar, mechanical engineering, ips college of technology management 2 hod, mechanical engineering, ips college of technology management, gwalior mp india email. The analysis has been conducted by using ansys12 software with the help of static structural tool. The suspension leaf spring is one of the potential. Static structural cae analysis of symmetrical 65si7 leaf. International journal of engineering trends and technology. Finite element analysis is done to predict the behavior of both the steel and composite leaf springs. Nonlinearity from large deformation, interleaf contact, and friction was included. The suspension system in a vehicle significantly affects the behavior of vehicle, i. A threelayer composite leaf spring with full length leave made of eglassepoxy composite material has been used. The suspension of leaf spring is the area which needs to focus to improve the suspensions of the vehicle for comfort ride.
A steel leaf spring used in the rear suspension of light passenger cars was analyzed by two analytical and finite element methods. No parameter value 1 gross vehicle weight 2150 kg 2 wheelbaseb 2680 mm 3 max speed 90 kmhr 4 engine mdi3000. So, a stress analysis was performed using finite element method. Nipping in leaf spring the stress in the full length leaves is 50% greater than the stress in the graduated leaves. 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. A finite element approach for analysis of multi leaf spring using cae tools research journal of recent sciencesvol 1,292,96feb 2012. The component chosen for analysis is a leaf spring which is an automotive component used to absorb vibrations induced during the motion of vehicle. In new light commercial vehicle development, engine is mounted at rear to have low engine noise and vibration inside cabin. Tension spring design becomes a much easier task when it comes to designing your tension springs at acxess spring. Static and dynamic analysis of automobile leaf spring tata ace. Stock plates will not accept our largerdiameter ubolts.
For this purpose, a rear leaf spring for mahindra modelcommander 650 di is considered. This condition may be obtained in the following two ways. The analytical calculation was carried out for conventional leaf spring. Design analysis and fabrication of composite mono leaf spring for automobile vehicle k. Keywords leaf spring, composites, catia, ansys, suspension system. 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.
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