Design & Development of Helical Compression Spring Using Composite Material

Abstract

The paper embodies the manufacturing of a helical compression spring using composite material. The main motive for the use of composite material spring is its low density and greater stiffness to that of a steel spring. The composite material spring has greater stiffness to weight ratio as compared to the steel spring. We have manufactured carbon fibre and glass fibre spring using filament winding technique as less as possible economical and effective. Various tests were performed on the spring using a load testing machine to find the spring rate, maximum compression, the maximum load the composite spring can sustain. We have plotted graphs about results we obtained while the testing which in detail shows the comparison of all three springs. We all know that corrosion is a natural process that changes metals to a more stable form; it is the destruction of the gradual material due to chemical or electrochemical reaction with the environment. Today corrosion is the main problem in the automotive industry. Well, the use of composite material is proving to fight back the problem of corrosion. In composite material, there are no chances of occurrences of corrosion. The weight of an electric car is 2050-3700kgs, where the weight of a battery of an electric vehicle is 385-544kgs. This means the battery alone weighs 26% of the total car weight which is affecting the electric car performance. To face this complication car manufacturers are using composite material for the fabrication of different car body parts. However, because of modern advancements currently, Boeing's latest plane, the 787 Dreamliner uses composites for half of its airframe including the fuselage and wing, while Airbus's A350 XWB has both its fuselage and wings made of carbon fibre.