Abstract
Design optimization of product with the objective of reducing weight is one of current focuses in a product design. In the vehicle industry, in particular, weight reduction has significant impact on vehicle efficiency improvement and the fuel economy. These improvements can have direct impact on operating costs of the vehicle. The methods used to weight reduction are by optimizing the product́s parameters and by replacing conventional materials with highly sustainable materials strengths. In this paper, design model of existing master leaf spring has been created and optimized using SolidWorks parametric optimization with a goal of reducing the weight of leaf spring, improving the life span of structure by reducing stress and increasing the natural frequency of the leaf spring. The constraint used was limiting stress and natural frequency with the leaf spring’s thickness and width as optimization variables. Optimum values of these parameters of the leaf spring were obtained. Again, using parametrically optimized leaf spring model static and modal analysis was studied under two different composite materials, Epoxy Carbon UD Prepreg and Epoxy E-Glass UD, aiming to get minimum weight and improved life span compared to steel material (55SiMn90). The result shows that the leaf spring of composite materials performed better in terms of the stress level, stiffness and the natural frequency. At the same time, the weight of the composite leaf spring has significantly reduced. In summary, the study concluded that composite leaf spring is better efficient compared with conventional leaf spring from steel.
Highlights
In the current global interest to reduce dependence on fossil fuels, one of the methods employed is improving vehicle efficiency and fuel economy in the transportation sector
It can be seen that the replacement of steel based leaf spring by Epoxy Carbon UD (230 GPa) Prepreg, EGlass/Epoxy leads to a significant weight reduction per leaf spring by 81% and 74.5% respectively
Master leaf spring was optimized by varying width and its thickness taking constraint natural frequency and maximum allowable stress with objective of reducing the weight of leaf spring under optimum minimum stress and maximum natural frequency
Summary
In the current global interest to reduce dependence on fossil fuels, one of the methods employed is improving vehicle efficiency and fuel economy in the transportation sector. At the same time, reducing vehicle weight has direct impact on the vehicle efficiency, fuel economy, and can potentially reduce vehicle operating costs [1]. Research shows that the suspension system accounts for 10% À 20% of the unsprung weight on which many modifications have been taken place over the time [2]. Ensuring optimum design of the suspension parts and the body of vehicle contributes to reduced weight, which has impact on fuel efficiency of the vehicle and improved riding qualities. Effective performance of the suspension system is directly related to the riding comfort and the vehicle safety. The leaf spring is the foremost important component of the suspension system, and its main func-
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