Composite Leaf Spring Research Articles

Mechanical characterization, and comparison of stress-induced on mono and multi-leaf spring from laminated composite material

Currently, one of the main issues in the automotive industry is the weight reduction of the body. In this study, analysis of multi from steel, and mono leaf spring from composite material and comparison of stress-induced on the applied load in finite element analysis was studied. The three-dimensional (3D) modeling of the leaf spring was done on SOLIDWORK 17 and analyzed using ANSYS R 18.1 workbench and the stacking sequence is, [45/0/0/0/0/0/-45/90] s. From static analysis, it is observed that weight reduction of leaf spring is achieved 70.01% in case of the composite than steel, and the equivalent stress-induced and deformation is carbon/epoxy composite leaf spring is 60% and 6.16% respectively less than steel leaf spring for the same load-carrying capacity respectively. From the study, it is concluded newly designed carbon/epoxy mono composite leaf spring has better performance than the steel leaf spring.

Research on the Application of New Composite Leaf Springs for Commercial Vehicles

As the main load bearing components of commercial vehicles, leaf springs are generally heavy, and the demand for lightweighting is very urgent. Due to its unique material structure, the composite leaf springs have excellent performance and significant weight reduction effects. In this paper, the heating time during the production of composite leaf springs is shortened, and the production efficiency is greatly improved by establishing a suitable temperature-pressure-time moldflow molding window. Through the preforming process, the original multi-channel and multi-cavity molding structure is combined with the linkage demolding structure to achieve quick demolding. Finally, the molding cycle of composite leaf springs is controlled within 5min. It has achieved the same technical level as foreign countries, and effectively solved the problems of slow molding of composite leaf springs and inabilities to meet the demand of mass production in the past, which is of great significance for the large-scale industrial production and application of composite leaf springs.

Spline-based shape optimization of large-scale composite leaf spring models using Bayesian strategies with multiple constraints

The presented paper describes a shape optimization workflow using Bayesian strategies. It is applied to a novel automotive axle system consisting of leaf springs made from glass fiber reinforced plastics (GFRP). Besides the primary objectives of cost and mass reduction, the assembly has to meet multiple technical constraints with respect to various loading conditions. The related large-scale finite element model is fully parameterized by splines, hence the general shape of the guide curve as well as the spring’s height, width and material properties can be altered by the corresponding workflow. For this purpose, a novel method is developed to automatically generate high-quality meshes depending on the geometry of the respective springs. The size and complexity of the model demands the implementation of efficient optimization techniques with a preferably small number of required response function evaluations. Therefore, an existing optimization framework is extended by state-of-the-art Bayesian methods, including different kernel combinations and multiple acquisition function approaches, which are then tested, evaluated and compared. To properly address the use of GFRP as spring material in the objective function, an appropriate cost model is derived. Emerging challenges, such as conflicting targets regarding direct material costs and potential lightweight measures, are considered and investigated. The intermediate steps of the developed optimization procedure are tested on various sample functions and simplified models. The entire workflow is finally applied to the complete model and evaluated. Concluding, ideas and possibilities in improving the optimization process, such as the use of models with varying complexity, are discussed.

Design Analysis and Weight Optimization of Mono Leaf Spring by Using ANSYS and Validation with Practical Testing

Abstract: The present paper having a work on Design and analysis of composite leaf spring. The analysis has been conducted by using ANSYS-14.5 workbench software with the help of static structural tool. Two composite leaf springs with full length leave made of E-Glass fiber and Carbon fiber composite material has been used. The results of Conventional steel leaf spring have been compared with the present results obtained for composite leaf spring. Carbon fiber material is better in strength and lighter in weight as compared to the conventional steel leaf spring as well as Glass fiber leaf spring. We worked on different loading condition to validated UTM result with hand calculation and ANSYS result.

Design and Analysis of a Heavy Vehicle Leaf Spring

ABSTRACT: Decreasing weight while expanding or keeping up quality of items is getting the chance to be very imperative research issue in this present day world. Composite materials are one of the material families which are pulling in analysts and being arrangements of such issue. In this paper we depict outline and investigation of composite leaf spring. The goal is to think about the stresses and weight sparing of composite leaf spring with that of steel leaf spring. The plan requirement is firmness. The Vehicle Industry has awesome enthusiasm for supplanting of steel leaf spring with that of composite leaf spring, since the composite materials has high quality to weight proportion, great consumption resistance. The material chose was glass fibre fortified polymer (E-glass/epoxy), carbon epoxy and graphite epoxy is utilized against regular steel. The outline parameters were chosen and dissected with the goal of limiting weight of the composite leaf spring when contrasted with the steel leaf spring. The leaf spring was displayed in catiav5r20 and the investigation was finished utilizing ANSYS 17.02 programming.

Optimization of Various Percentage of Fibers in Fiber Reinforced Composite Material Leaf Springs in Vehicles

A spring steel leaf spring is commonly used for suspension system in all types of loading vehicles due to its good stiffness and fatigue strength. Today, spring steel leaf springs are used in majority of applications but they are heavy in weight, poor in terms of gets corrosion resistance and average in ride comfort. Fiber reinforced composite material leaf spring represents a key application of composite materials in the field of automotive vehicles due to improved ride comfort and light in weight. Stiffness, fatigue life and damping capacity are the critical parameter of fiber reinforced composite leaf springs. CAE software and experimental analysis have been mainly used for design and analysis for composite material leaf springs. Saman Jolaiy et.al. [2021] focused on the damping characteristics of the composite leaf springs and worked out that fabrication of composite leaf spring with viscoelastic core(2mm) decreases the damping ratio of the leaf spring system, which results in a smooth ride. Few studies evaluated the stress distribution, deflection and fatigue life assessment of composite leaf springs reinforced with glass fibers or carbon fibers or combination of carbon lass and carbon fibers. The main objective of the present work is to optimize various percentage of fiber reinforced composite material leaf springs along with insertion of viscous core. The optimized results thus obtained show that the fiber reinforced composite leaf springs with viscous core can be a good replacement of spring steel leaf springs with overall weight reduction and better damping characteristics. Replacing spring steel leaf springs with fiber reinforced composite leaf springs will improve safety, comfort, high elastic strain energy storage capacity and durability.

Investigation regarding the Replacement of Composite Material Leaf Springs with Spring Steel Leaf Springs in Automotive Vehicles: A Review

Leaf Springs finds vast applications in different types of mechanical systems. In spite of lot of research, spring steel leaf springs finds a lot of applications in all types of heavy vehicle. Composite leaf springs represent some application of composite materials in the field of automotive lightweight materials. However, the composite material finds limited applications in the form of mono leaf but for multi leaf in heavy vehicles, its application is rare due to certain issues including delamination. Stiffness and damping properties are the critical parameter of composite leaf springs and are closely related to the handling stability and ride comfort of automobiles. Composite leaf spring with variable parameters may be used in the automobiles to replace the conventional steel leaf springs, mainly due to the high load-bearing capacity. The optimum structural design of composite leaf spring may be calculated using an effective algorithm. The mechanical properties of composite leaf spring is analyzed with experimental or computational approach or both. This paper investigates addresses various issues regarding the replacement of composite material leaf springs with spring steel leaf springs in light and heavy weight automotive vehicles.

Analyzing the Fatigue Behaviour of E-Glass Fiber Reinforced Interpenetrating Polymer Networks (EP/VP/EV) Leaf Spring

Conventional steel springs have gradually been replaced with composite materials due to their inherit properties like high strength-to-weight ratio, relatively inexpensive ratio, and resistance against corrosion. Also, fiberglass reinforced plastic usages and its implementation is subjected in variety of fields such as vehicle and locomotive bogies, heavy commercial vehicles like vans and trucks. The current study looks at a composite material that can be used in the composite leaf spring suspension system. In this particular research, several blends of interpenetrating polymer networks (IPNs) have been used as the matrix material with the reinforcement of E-Glass fiber. The implemented combination blends are epoxy with polyurethane (EP), vinyl ester with polyurethane (VP) and epoxy and vinyl ester (EV). However, this research work also examines the characterisation and physical properties of the composite material leaf spring (CMLS) in narrow manner. Consecutively, tests were carried out for three types of composites by varying the various blend ratios of IPNs with the standard reinforcement of E-Glass fiber. Besides, to evaluate and compare their individual uniqueness, their physical characteristics tests like compression test, hardness test, tension and cyclic load parameters are found and their corresponding results were compared with each other.

A Review Paper on Design and Analysis of Leaf Spring

Abstract: This paper reviews some of the general study on the design, analysis and fabrication of composite leaf spring. Leaf springs are one of the oldest suspension components they are still frequently used, especially in commercial vehicles. The literature has indicated a growing interest in the replacement of steel spring with composite leaf spring.The suspension system in a vehicle significantly affects the behavior of vehicle, i.e. vibration characteristics including ride comfort, stability etc. Leaf springs are commonly used in the vehicle suspension system and are subjected to millions of varying stress cycles leading to fatigue failure. A lot of research has been done for improving the performance of leaf spring. Lot of materials are used for leaf spring .but it is found that fiberglass material has better strengthcharacteristic and lighter in weight as compare to steel for leaf spring. In this paper the author is reviewed few papers on use of alternate materials and effect of material on leaf spring performance. Keywords: steel leaf spring, ANSYS, PRO-E software.

Analysis of stiffness and damping performance of the composite leaf spring

Lightweight design of leaf springs is conducive to reducing fuel consumption and improving vehicle comfort. The weight of leaf spring can be reduced obviously by using composite material. Stiffness and damping are the key factors that affect the properties of the leaf spring. The influence of the glass fiber laying angle and volume content on the stiffness and damping of the composite leaf spring was analyzed through experiment and simulation. The results show that the stiffness and damping properties of the leaf springs are related to the fiber laying angle and the fiber volume content. When the volume content and the number of layers are constant, the stiffness shows a nonlinear decreasing relationship with the laying angle, and the damping coefficient increases linearly with the laying angle. When the laying angle and the number of layers are constant, the stiffness increases linearly with the fiber volume content; the damping coefficient has a nonlinear decreasing relationship with the fiber volume content. The type of research can provide theoretical basis and reference for the design, analysis and optimization of composite leaf spring.

DESIGN, ANALYSIS AND COMPARISON BETWEEN COMPOSITE MATERIALS WITH CONVENTIONAL MATERIAL OF LEAF SPRING

This paper reveals the investigation of composite leaf spring and themodeling of the leaf spring with the use of different composite materials. The automobile industries are more competitive with low mass density with higher strength. Here is the work that compares the different composite leaf spring in which the parameters are considered such as static analysis and dynamic analysis. The modelingg of the composite leaf spring is done in SOLIDWORKS and then the static analysis is performed in ANSYS Workbench. It is also done in SOLIDWORKS to compare both the results and the dynamic analysis is also performed in the SOLIDWORKS software. A comparison has been made between laminated composite leaf springs, the materials are carbon steel grade (SUP9), S2 Glass Fibre, and Carbon Fibre(T300) which are having the same design and same load-carrying capacity. From that 79.22% weight reduction in composite material has been achieved for the same number of leaves and also high natural frequencies compared with other composites. From the result, the composite material of carbon fibre (T300) is best for leaf spring manufacturing.

A Review of Comparative Analysis of Bamboo Fiber Reinforced Glassfiber Leaf Spring with Conventional Leafspring

Abstract: Leafspring is one of the oldest and most effective suspension systems. Today it can be seen used in all heavy commercial vehicles the leaf spring used conventionally was made up of plain carbon steel, silicon manganese steel etc. but as steel is heavy it increases the overall weight of vehicles and decreases its performance, but nowadays after the advent of composites many researchers are trying to replace conventional leafspring with new composite leafsprings which are light in weight. In our project we are trying to compare and analyse two such composite material made up of bamboo fiber reinforced with s-glassfiber and bamboo fiber reinforced with e-glass fiber using epoxy resin matrix with conventional leafspring. Keywords: Bamboo fiber ,s-glass fiber, e-glass fiber, leafspring, epoxy resin

Theoretical and finite element analysis (FEA) of coated composite leaf spring for heavy-duty truck application

There is always increase in demand of extended application of automobile parts due to long spanning life, weight reduction and high performance. Conventional steel leaf is lagging behind in automobile industries due to replacement by composite materials as a result of weight reduction and excellent mechanical properties. The research aim is to compare the theoretical and finite element analysis of coated composite materials for heavy duty application by giving enhanced von misses stress and better deflection. CATIAVR9 and ANSYS software were both used for the model and the numerical analyses of both the coated composite materials and the conventional steel leaf.Weight reduction and strength enhancement were experienced by composite leaf spring with E-glass/epoxy showing 7.95% weight reduction, carbon epoxy 8.50%, bamboo polyester 8.8% and graphite epoxy 8.5%. when compared with conventional steel leaf spring. Maximum displacement shown by E-glass/epoxy was 0.65088 mm, graphite epoxy with displacement of 0.66416 mm, carbon epoxy with displacement of 0.6677 mm and bamboo polyester displacement with 0.67647 mm when the composite leaf springs were coated with molybdenum. The conventional leaf spring showed von mises stress of 508.33 MPa via the static analysis results. While von mises stresses shown by the composite materials were 459.16 MPa for bamboo polyester, 423.3 MPa for graphite epoxy, 463.5 MPa for carbon epoxy and the lowest stress of 406.6 MPa came from E-glass/epoxy material. Lower stresses and displacements were shown by composite leaf springs four models as compared to conventional steel leaf spring. With coated composite leaf spring, weight reduction of 5.55% was shown for bamboo polyester, carbon epoxy with 4.97%, graphite epoxy with 4.87 wt reduction and E-glass/epoxy with 4.585% weight reduction.

Achieving safety and weight reduction in automobiles with the application of composite material

In the present scenario of cutthroat competition in automobile industry, the importance for sleek and efficient models of automobiles with aesthetics and passenger comfort is paramount. In addition to the comforts like air conditioning and spaciousness etc., the ‘suspension’ is also significant in the selection of an automobile. The main focus of this paper is on weight reduction by replacing conventional spring steels with composite materials. A successful attempt has been made at Gokaraju Rangaraju Institute of Engineering and Technology, Hyderabad laboratories to fabricate the composite leaf spring, which is having equivalent properties of Maruti800 car leaf spring. The transverse failures in steel leaf springs lead to rear axle dislocation. This problem could be successfully eliminated with composite leaf springs since the general failure in unidirectional reinforcement composites is in longitudinal direction. This paper suggests the design improvements in this direction.

Investigation on Mechanical Properties of Carbon Fiber Composite Using FEM for Leaf Spring Applications

Nowadays, many industries are shown interest in the hybrid composites, natural fibers, and reinforced materials due to reduction of the weight. The reason is that it will not affect environmental conditions. This experimental investigation identified the mechanical properties of hybrid composites. The hybrid composite materials are extensively used by E-glass/epoxy, carbon, and titanium alloy. Composites have good strength and less weight. The highest challenge of the automobile industry is to replace the steel leaf spring instead of the composite leaf spring. The composite structures have been providing better corrosion resistance. The conventional leaf spring experimental results were compared to analytical results of composite leaf spring. The design, simulation, and maximum stresses were done with the help of Ansys Workbench 15. Ansys Workbench materials are selected by titanium alloy, epoxy glass, aluminum alloy, and epoxy carbon. The design parameters were selected and analyzed to compare stress, deformation, elastic strain, and weight of the composite leaf spring as compared to conventional steel leaf spring. Deflection results were identified in the mechanical properties of the leaf spring. It should absorb shock loads and vertical vibrations due to road abnormalities. The composite experimental samples were analyzed using scanning electron microscopy.

Vol4 num4-5 Development and characterization of a composite leaf spring, with bucking working

For a long time, metal leaf springs have been used as elastic element, merging them with helicoidal spring for suspension applications. This type of system based on ferrous materials combined in independents plies, presents multiple problems such as interface friction, or its poor behavior in plastic state. These conditions lead to a mechanical property lost through a period of time, evoking fatige problems. Throughout this project a high strength unidirectional leaf spring based on glass fiber composite material has been developed with the purpose of solving these problems. To ensure an adequate service life, an bicomponet based material has been selected, improving its process. CRTM has been chosen for the processing of the prototypes. Finally, taking other related problems away is possible thanks to multiple CAD implementations tools. So with this as the backdrop, a one blade leaf spring under a buckling situation has been designed, solving all the existing problems found in current iron technology. Under the scope of industrial implementation and optimization, composite advantages related with flexibility and lightweight can be resourceful.

Design optimization and numerical analyses of composite leaf spring in a heavy-duty truck vehicle

The suspension in automotive has been carried out for years by steel leaf spring. Despite this, the issue of emission and efficiency of fuel in automotive has remained in the forefront as one of the draw backs in automotive industry. This drawback can be solved by providing vehicles that are cost effective and gives fuel efficiency in terms of weight reduction in automobile. This is achievable by replacing steel leaf spring with composite materials with enhanced properties which can compare favorably with steel leaf. This is due to the fact the weight of a vehicle is carried by steel leaf spring. The aim of this research work is to optimize the design of the steel leaf spring by replacing it with composite materials for an extended application in automotive industry. The economic advantage and enhanced mechanical properties of composite materials like carbon epoxy, bamboo polyester, E-glass/epoxy and graphite epoxy made them choicy materials to be compared with the conventional steel leaf. CATIAVR9 and ANSYS software were both used for the model and the numerical analyses of the composite materials and the steel leaf. The results showed that all the four composite materials exhibited weight reduction compared to the conventional steel leaf. The Von Misses stresses of the composite materials were also compared with the conventional steel leaf and the results corroborated. Bamboo polyester showed maximum displacement of 1.5726 mm and followed by Carbon epoxy with deflection of 1.5469 mm. E-glass/epoxy showed the lowest displacement of 1.5172 mm as compared to conventional steel leaf with displacement of 1.2144 mm.

Numerical Analysis of A Nonlinear Elastic Composite Leaf Spring

In this study, numerical analysis of a composite spring with a nonlinear elastic force-displacement relationship was performed. Due to the lightness and durability of composite materials, their use in the automotive industry is increasing and production methods allow for a high performance spring design. The behavior of a pair of composite leaf springs working in tandem with the cross-section profiles of the leaf springs to be obtained by using the involute curve of the spur gear pairs under load was examined in detail by numerical method, and the desired behavior was obtained. In the analyzes performed using Ls-Dyna software, samples were produced and many mechanical tests were performed for the determination of material parameters. The results obtained from these tests were used as the required material parameters in numerical analysis. The leaf spring thickness that will give the desired non-linear elastic behavior under 400 N load used in numerical analysis has been determined and successfully targeted force-elongation behavior has been created.

Finite element analysis of Epoxy/E-Glass composite material based mono leaf spring for light weight vehicle

A great deal of work is put into decreasing the fuel consumption of automotive vehicles, which may be accomplished by reducing the bulk of the vehicles. One component that may be explored is the leaf spring, which is extensively utilized in many sorts of cars, including electric ones. For the leaf spring, four distinct materials are considered: standard steel, Epoxy/E-Glass UD composite, Epoxy/E-Glass Wet composite, and Epoxy/S-Glass UD composite. The FEA study executed with the help of the ANSYS finite element code. Firstly, the 3-D model of the leaf spring with different thickness varying from 15mm to 65mm is designed using SolidWorks software which is then imported to the ANSYS software for the static analysis. Along with this, the finite element analysis under full load on 3-D composite multi leaf spring model is executed using ANSYS 2020 R1 by taking three different materials and then the result for the different static behaviour of the leaf spring are compared for all the materials assigned. In this paper we describe design and analysis of composite leaf spring. The leaf spring model used for this purpose is a rear leaf spring used in MAHINDRA “MODEL-COMMANDER 650 DI”. When compared to traditional steel, the mass of hybrid composite material is 62% lower. Hybrid composite materials have 36% lower equivalent (Von-Mises) stress than steel. Utlimately, the hybrid composite material may be employed as a leaf spring, decreasing the total weight of automobiles.

Experimental analysis of composite materials leaf spring used in automotive

product modifications or replacement of old products with new and improved material items. Vehicle suspension systems are another area where these developments are carried out on a regular basis. More efforts are being made to improve the user's comfort. Appropriate combination of comfort riding attributes and economics in leaf spring production becomes an evident requirement. Many changes have been made to the suspension system throughout time in order to enhance it. Some of the most recent suspension system innovations include the invention of the parabolic leaf spring and the usage of composite materials for these springs. The implementation of composite materials by replacing steel in conventional leaf springs of a suspension system. Composite material having a lot of good properties like simple fabrication, low weight and low cost to performance .The purpose of this study is to investigate the structural properties of a hybrid leaf spring consisting of 95% Epoxy, 5% carbon, 5% glass fiber, and 5% hybrid carbon-glass fiber composite. The various specimens were produced using the manual layup method, specimen were subjected to tensile, hardness, and fatigue tests, with all data reported and compared. The experimental results showed an increase in Hardness, Tensile, and fatigue life when the reinforcing fibers are applied. The best results of the mechanical test obtained when hybrid reinforcement was applied.