Conventional Steel Leaf Spring Research Articles

Comparative analysis of static and vibration characteristics of glass fiber reinforced epoxy mono composite leaf spring and conventional steel leaf spring

Leaf springs play a vital role in heavy-duty vehicles by offering substantial load support, durability, and convenient maintenance. Lightweight leaf springs enhance vehicle performance, offering benefits like improved fuel efficiency and a smoother ride. Glass fiber reinforced composites enhance fuel efficiency and durability, providing corrosion resistance. Their design flexibility improves ride comfort, and damping properties enhance vehicle stability. The examination conducted through finite element analysis, utilizing ANSYS software, demonstrated a substantial 75.32% decrease in weight for the E-Glass-Epoxy composite leaf spring (GECLS), affirming its efficacy in enhancing strength, reducing weight, and enhancing stiffness. This underscores its superiority as a viable alternative to traditional steel leaf springs (SLS) in vehicular applications. The mono-GECLS exhibited a natural frequency that was found to be 1.9 times higher than that observed in the traditional SLS. It indicates the potential to mitigate resonance issues. After analysing the SLS and GECLS using ANSYS, it was observed that the GECLS exhibits greater values in deflection, natural frequency, and strain energy, measuring 4.659 mm, 29.98 Hz, and 440.68 mJ, respectively, compared to its steel counterpart. Conversely, the SLS demonstrates elevated values in stress, mass, and density, with readings of 283.84 MPa, 3.7695 kg, and 5920 kg/m³, respectively.

Design and Analysis of Leaf Spring Using Ansys

Abstract: The leaf springs are different spring styles used for automotive suspension systems. In addition to the use of energy absorption equipment, the ends of the spring can be pointed in a certain direction as it deflects as a structural function. Not primarily supporting vertical loads but isolating road-induced vibration is the principal feature of leaf spring. The present research aims at studying the safe load of the leaf spring, showing how easily an easy, safe driving speed is achieved. A standard TATA-407 light commercial vehicle leaf spring configuration is chosen. Finite element analysis for safe stresses and pay loads has been done. Conventional materials and alternative materials in spring construction used in the present work have been studied. Computer aided designing (CAD) is being widely used in different industries for product testing and manufacturing, this paper consist of design and analysis of leaf spring using ANSYS 19.2. Static structural tool has been used of ANSYS. 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. High elastic material springs are used which possess maximum strength and fatigue effects. Weight reduction is one of the major concern while designing a vehicle as it helps in design optimization and fuel economy’s three layer composite leaf spring with full length leave. E-glass/Epoxy composite material has been used and is compared with conventional steel leaf spring. After conducting various tests it is found that eglass/epoxymaterial is better in strength and lighter in weight as contrast with conventional steel leaf spring.

Static analysis on mono composite leaf spring for Maruti 800 light vehicles

In this paper design and analysis of composite leaf spring made of glassfiber reinforced polymer (GFRP) and sisal fiber reinforced polymer (SFRP). In addition, to compare the load carrying capacity, stiffness and weight savings of composite leaf spring with that of steel leaf spring. The dimensions of conventional steel leaf spring are used to fabricate a composite mono leaf spring using GFRP unidirectional laminates. Static analysis of 2-D model of conventional leaf spring is also performed using Finite Element Analysis (FEA) and compared with experimental results. and the analytical results are compared with experimental results from the analysis it is observed that Sisal fiber /Epoxy mono composite leaf spring showing best results as compared to the other materials

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.

“Experimental and FEA Investigation of V Shape Spring with Materials”

The Automobile Industry has shown keen interest for replacement of steel leaf spring with that of progressive rate spring unit, since that has good part loading and minor to maximum shock absorption properties. In this paper we have outline on the new mechanism for progressive rate spring. The main leaf spring and V- shape strip spring model is created by modeling software like Pro-E. The dimensions of an existing conventional steel leaf spring of a light commercial vehicle are taken for modeling. And the structural analysis of both springs is carried via finite element analysis using ANSYS-12 software. Result shows that, the V-shape strip spring has Total deflection 16.93 % & Strain energy 38.20 % more than steel leaf Spring for partly loading. It also shows equivalent von- misses stresses for both spring. It is observed that the V- shape strip spring is great under part loading i.e. minimum loading action and main leaf spring is superior for maximum loading condition so that the whole unit of this progressive rate spring is best suitable for carrying export quality fruit from farm to wear house or customer market and mini ambulance vehicle. All material used in this unit is easily available, so it commercially adopted in automotive mini trailer manufacturer. Also it has less complexity and economically advantageous for middle class farmer.

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.

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.

DESIGN AND ANALYSIS OF COMPOSITE LEAF SPRING

This paper describes the design and experimental analysis of composite leaf spring made of glass fibre reinforced polymer. The main aim is to compare the load-carrying capacity, stiffness and weight savings of composite leaf spring with that of steel leaf spring. The design constraints are stress and deflection. The dimensions of an existing conventional steel leaf spring of a light commercial vehicle were considered for the present work. A traditional composite multi-leaf spring was fabricated with the same dimensions using E- Glass/Epoxy unidirectional laminates. Static analysis of 2D model of conventional leaf spring has also been performed using ANSYS 10 and compared with experimental results. Finite element analysis with a full load on the 3-D model of composite multileaf spring was performed using ANSYS, and the analytical results were compared with experimental results

Experimental analysis of E-glass fiber/epoxy composite-material leaf spring used in automotive

Nowadays, conventional springs are replaced with the composite material having a lot of better properties like low weight, simple fabrication and low cost to performance. Environmental awareness all over the world has developed attention in the composite material and its application in different areas. In the present work, a composite material is considered for the application of suspension system leaf spring. In this paper composite-material leaf spring (CMLS) has been studied for its characterization and mechanical properties. In this work, a rear leaf spring of Mahindra pickup made of conventional steel leaf spring (CSLS) has been used. A hand lay-up fabrication technique was used to make the CMLS. Matrix (epoxy resin and hardener) and E-Glass fiber are used as a composite material. Composite-material leaf spring was fabricated and material properties like hardness and bending behavior were investigated. It was found that 79.13% of the weight is reduced. From the Experimental results, the strength of CMLS was nearer to the properties of CSLS. Weight fraction and the design of the CMLS also effect on the bending and hardness of composite-material leaf spring. Scanning Electron Microscope (SEM) analysis is also done to recognize the microstructure of CMLS.

Static Analysis and Fatigue Life Prediction of Composite Leaf Springs of Automotive Suspension System

Development of vehicles with the highest safety standards and lowest carbon emissions has been one of the primary goals of the automobile manufacturers. One of the methods of achieving higher fuel efficiency is by reducing vehicle weight by minimizing the unsprung weight without compromising strength and driver comfort. The study presents the behavior of the double-bolted-end joint semi-elliptical leaf spring that is generally used in the rear suspension of lightweight cars and commercial vehicles. 65si7 grade steel is conventionally used in the above leaf springs. The study evaluates the stress distribution, deflection and fatigue life assessment of leaf springs made up of glass epoxy (62% glass fiber), carbon epoxy (40% carbon fiber), and aluminum graphite (5% graphite). The results are compared with 65si7 steel leaf spring and analysed. The analysis performed showed a weight reduction of 76.4 %, 81.1%, 65.8% respectively. The first natural frequency was approximately 1.2 times greater than the road frequency. The simulated results for fatigue life cycles of leaf spring (10e5 cycles) was observed, whereas, for the conventional steel leaf spring (2e5 cycles) was observed. The results suggest the material aluminum graphite (5% graphite) will be the best replacement, considering the overall weight to strength ratio and cost.

Static and Vibration Analysis of CFRP Composite Mono Leaf Spring

Conventional steel leaf spring is analyzed at maximum load using finite element analysis (FEA), ANSYS v16 software. The finite element results showed stresses and deflection, and then by using the results of the steel leaf spring, a composite one made from carbon fiber with epoxy resin CFRP is designed using FEA. The objective was to obtain safe design of CFRP composite leaf spring with less weight and the same stiffness of that the steel one. In the study, safe design means that CFRP composite leaf spring has high safety factor in stresses and high natural frequencies. Static, modal and harmonic analysis for both steel and composite leaf springs has been carried out using FEA. The results showed that the CFRP composite leaf spring withstands against failure and resonance where it has much higher factor of safety in stresses and higher natural frequencies with weight reduction 79% over conventional steel leaf spring.

Performance of leaf springs made of composite material subjected to low frequency impact loading

This paper illustrates the possibility of replacing existing conventional steel-leaf spring by the leaf spring made by tailoring the layup of composite laminates. The dimensions of the existing conventional middle leaf (spring) of a commercial vehicle were chosen for the design and manufacture of die for moulding the composite leaves. Accordingly, suspension springs of composites of different layups with glass and carbon were fabricated and tested for flexure response. It is to be noted here that the cross sectional area of the composite leaf spring was the same as of the conventional leaf spring. By using universal testing machine, load per deflection and maximum load for each of the composite leaf springs were evaluated. Apart from these, the specimens were exposed to low frequency impact loading with specific duration of cycles and subsequently the flexure response was also evaluated. The low frequency impact on the composite leafs was effected with a laboratory loading set-up in a milling machine. Experimental results indicated the superior flexure response of the hybrid composites (with glass fiber at starting phase and carbon fiber at the end) and suggested possible alternative on comparison with the conventional spring.

Performance Analysis of Composite Leaf Spring Using Computer Aided Engineering

Automobile industries have shown more interest for the replacement of conventional steel leaf spring with that of the composite leaf spring due to its high strength to weight ratio. The objective of the work is to carry out computer aided design and analysis of composite (Glass fiber reinforced plastic) leaf spring and conventional steel leaf spring by considering certain parameters like stress, deflection and strain energy with similar design considerations and loading conditions. The material of the conventional leaf spring is 65Si7 and composite leaf spring is S2-Glass\Epoxy. The CAD model of the leaf spring is modeled in Pro-E and the numerical analysis is carried out using finite element analysis, ANSYS 14. Stress, deflection and strain energy results of both steel and composite leaf spring are obtained and compared. The result shows that the composite leaf spring has maximum strain energy than conventional steel leaf spring and weight of the composite leaf spring is nearly reduced up to 85% compared with steel material.

Comparative FEM Analysis of V-Shape and Leaf Springs for Improved Suspension with Part Loading Functionality

The Automobile Industry has shown keen interest for replacement of steel leaf spring with that of progressive rate spring unit, since that has good part loading and minor to maximum shock absorption properties. In this paper we have outline on the new mechanism for progressive rate spring. The main leaf spring and V- shape strip spring model is created by modeling software like Pro-E. The dimensions of an existing conventional steel leaf spring of a light commercial vehicle are taken for modeling. And the structural analysis of both springs is carried via finite element analysis using ANSYS-12 software. Result shows that, the V-shape strip spring has Total deflection 16.93 % & Strain energy 38.20 % more than steel leaf Spring for partly loading. It also shows equivalent von- misses stresses for both spring. It is observed that the V- shape strip spring is great under part loading i.e. minimum loading action and main leaf spring is superior for maximum loading condition so that the whole unit of this progressive rate spring is best suitable for carrying export quality fruit from farm to wear house or customer market and mini ambulance vehicle. All material used in this unit is easily available, so it commercially adopted in automotive mini trailer manufacturer. Also it has less complexity and economically advantageous for middle class farmer.

Analysis of Steel and Composite Leaf Spring for Vehicle

The Automobile Industry has shown keen interest for replacement of steel leaf spring with that of glass fiber composite leaf spring, since the composite material has high strength to weight ratio, good corrosion resistance and tailor-able properties. The present study searches the new material for leaf spring. In present study the material selected was glass fiber reinforced plastic (GFRP) and the polyester resin (NETPOL 1011) (5) is used against conventional steel. A spring with constant width and thickness was fabricated by hand lay-up technique which was very simple and economical. The numerical analysis is carried via finite element analysis using ANSYS software. Stresses, deflection and strain energy results for both steel and composite leaf spring material were obtained. Result shows that, the composite spring has maximum strain energy than steel leaf spring and weight of composite spring was nearly reduced up to 85% compared with steel material. This paper describes design and FEA analysis of composite leaf spring made of glass fibre reinforced polymer. The dimensions of an existing conventional steel leaf spring of a light commercial vehicle are taken for evaluation of results. I. Introduction Finite Element analysis tools offer the tremendous advantage of enabling design teams to consider virtually any molding option without incurring the expense associated with manufacturing and machine time. The Ability to try new designs or concepts on the computer gives the opportunity to eliminate problems before beginning production. Additionally, designers can quickly and easily determine the sensitivity of specific molding Parameters on the quality and production of the final part. The leaf spring model is created by modeling software like pro-E , Catia and it is imported in to the analysis software and the loading, boundary conditions are given to the imported model and result are evaluated by post processor. The different comparative results of steel leaf spring and composite leaf spring are obtained to predict the advantages of composite leaf spring for a vehicle. II. FEA (Finite Element Analysis) FEA tool is the mathematical idealization of real system. Is a computer based method that breaks geometry into element and link a series of equation to each, which are then solved simultaneously to evaluate the behavior of the entire system. It is useful for problem with complicated geometry, loading, and material properties where exact analytical solution are difficult to obtain. Most often used for structural, thermal, fluid analysis, but widely applicable for other type of analysis and simulation

Simulated annealing approach to the optimal design of automotive suspension systems

This paper presents an approach for the design optimisation of suspension springs, such as coil springs, torsion bar springs, steel leaf springs and composite leaf springs, using a Simulated Annealing algorithm. Around 14.39% of coil spring mass and 7.12% of torsion bar spring mass are reduced. In the case of steel leaf springs, 14.40% of mass, under two variables condition and 16.58% of mass, under three variables condition are reduced. Similarly, 22.93% of mass under two variables condition and 29.28% of mass under three variables condition are reduced in the optimisation process of composite leaf springs. When the composite leaf spring is compared with the conventional steel leaf spring, the mass reduction obtained before optimisation is 83.52% and mass reduction obtained after optimisation is 85.16% in the case of two variables condition and 86.03% in the case of three variables condition for the same load carrying capacity and stiffness.