Scribd
Upload
60 views5 pages

Design & Analysis of Mono Composite Leaf Spring: Volume 2 Issue2 PP 103-107 May 2013

The document discusses the design and analysis of a composite leaf spring made of fiber reinforced polymer to replace a conventional steel multi-leaf spring. It describes modeling a composite leaf spring in CATIA and analyzing it in ANSYS under different loading conditions. Results for stresses and deflections are presented and compared to those of a modeled steel leaf spring.

Uploaded by

Rajesh Kumar P
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
60 views5 pages

Design & Analysis of Mono Composite Leaf Spring: Volume 2 Issue2 PP 103-107 May 2013

The document discusses the design and analysis of a composite leaf spring made of fiber reinforced polymer to replace a conventional steel multi-leaf spring. It describes modeling a composite leaf spring in CATIA and analyzing it in ANSYS under different loading conditions. Results for stresses and deflections are presented and compared to those of a modeled steel leaf spring.

Uploaded by

Rajesh Kumar P
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 5

International Journal of Scientific Research Engineering & Technology (IJSRET)

Volume 2 Issue2 pp 103-107 May 2013


www.ijsret.org
ISSN 2278 0882

Design & Analysis of Mono Composite Leaf Spring


R D V Prasad1, R.Sai Srinu2 , P.Venkata rao3
Asst.Prof1, M.Tech Student2, Asst.Prof3
Asst.Professor Department of Mechanical Engineering, Bits Vizag, Andhra Pradesh, India.
2
M.Tech Student of Andhra University, Vizag. Andhra Pradesh, India.
3
Asst.Professor Department of Chemical Engineering, Andhra University, Vizag, Andhra Pradesh, India.
1

ABSTRACT
Leaf Spring is a critical load bearing element
that connects wheel to the chasis in an automobile
application. The Suspension leaf spring of one of the
potential items for weight reduction in automobiles in
order to achieve increased fuel efficiency and
improved ride characteristics. The introduction of fiber
reinforced plastics (FRP) made it possible to reduce
weight of the product without any reduction in load
carrying capacity and stiffness. Because of the
materials high elastic strain energy storage capacity
and high strength-to- weight ratio compared with those
of the steel, multi leaf springs are being replaced by
mono Leaf FRP springs.
This paper deals with development of
analytical formulation for Composite leaf spring and
comparing the obtained results with the Conventional
Steel leaf spring with 4 leaves. Composite leaf spring
in this project has been developed as a mono block
construction with maximum thickness at the center
which is preferably glass fiber reinforced polymer. The
thickness reduces towards the end in order to achieve
uniform strength construction. The cross-section is
constant at any section along the spring length. This
condition is imposed to accommodate the
unidirectional fibers and to maintain the fiber
continuity from one end to the other.
At first we designed a conventional Leaf
spring with 4 leaves using ANSYS 11 and considered
different loading conditions to obtain Stresses and
Deflections. The dimensions of an existing
conventional steel leaf spring of a light commercial
vehicle are taken. Then we created a Solid Model of
Composite leaf spring using CATIA V5 and imposed
different loading conditions.
Key words leaf spring, ERP springs, glass fiber
reinforced polymer.

I. INTRODUCTION
A spring is an elastic body whose function is to distort
when loaded and to recover its original shape when the
load is removed. Though there are many types of
springs, the following, according to their shape are
important. The various applications of springs are to
cushion, absorb or control energy due to either shock
or vibration, as in car springs, railway buffers, aircraft
landing gears and vibration dampers. To apply forces,
as in spring-loaded valves and spring balances. To
control motion by maintaining contact between two
elements as in cams and followers. To measure forces
as in engine indicators and spring balances. To store
energy as in watches and toys.

II. LITERATURE SURVEY


JOHN
E.MUTZNER
and
DAVID
S.RICHARD[1] told in their paper titled
Development And Testing Of Composite Truck
Trailer Spring that, composite leaf spring constructed
of glass fiber reinforced polymeric material have been
recognized as a variable replacement for steel leaf
springs since their introduction on the 1981 general
motors covette. This acceptance of composite leaf
springs has given rise to applications in high volume
production passenger cars and utility of composite leaf
spring is clearly demonstrated in these applications.
This paper will discuss the design, laboratory testing,
field testing, and development over the past three years
that has led to the commercialization of the liteflex
trailer springs. This will include the design process for
high and low deflection composite leaf spring and
stress analysis for common springs used in various
axle spacing worldwide. An explanation of laboratory
test will be given and the rationalization for these test
compared to steel spring test standards. An attempt
will be made to correlate laboratory test tracks, servo
hydraulic simulator and field tests of liteflex trailer

IJSRET @ 2013

International Journal of Scientific Research Engineering & Technology (IJSRET)


Volume 2 Issue2 pp 103-107 May 2013
www.ijsret.org
ISSN 2278 0882

springs. This testing will demonstrate the soft failure


mode if the composite leaf spring and the advantage
this brings to fleet owners. The other advantage of
weight reduction and increased durability will be
discussed.
KIKUA TANABE, TAKASHI SEINO[2] of
Central Engineering Laboratories, Nissan Motors co.,
ltd. Yokosuka, Japan in their paper titled
Characteristics Of Carbon/Glass Fiber Reinforced
Plastic Leaf Spring designed and fabricated and
evaluated a tapered leaf spring made of carbon fiber
reinforced plastics. To construct the leaf spring, a
carbon/glass fiber hybrid lamination is selected. This
selection was made in concentration of chipping
resistance, impact resistance and fatigue resistance.
They constructed a prototype of leaf spring which
weighed approximately 2kg included the front and rear
steel eyes. In comparison with the steel spring, this
represents a weight reduction of 76%. Prototype are
put through a series of evaluations both on the bench
and on the vehicle. As a result, the leaf spring proved
to be better than the steel in such practical performance
area as car handling and riding quality and endurance.

III MODELLING OF FRP LEAF SPRING


We have designed a solid leaf spring with all
required dimensions as we calculated earlier. We
designed this solid leaf Spring using CATIA V5
Software.

The element used is SOLID 45(3-D four node


tetrahedral structural solid with rotations).
Solid 45 is well suited to model irregular
meshes (such as produced from various CAD/CAM
systems). The element is defined by four nodes having
six degrees of freedom at each node; translations in the
nodal x, y, z directions and rotations about the nodal x,
y and z directions. The element also has the stress
stiffening capability. The SOLID 45 element can often
be used in place of the SOLID 92 element to reduce
the wave front and solution time.

IV. NOMENCLATURE
R- Radius of curvature of Arc
M- Bending Moment acting at that point
I- Moment of Inertia of spring section at the point
y- Distance of extreme fiber from Neutral axis
fb- Bending Stress
b- Width
P- Static load per wheel
W- Laden weight of the vehicl
db- Bolt diameter
4.1 SPECIFICATIONS (passenger vehicle):
Laden load - 14 tones
Number of springs supporting the load - 4
Span of the spring
- 1000mm
Number of leaves
- 4
Permissible deflection - 85mm
Table 1 Mechanical properties of N155 & Inconel
718
SL.No Properties
Value
1
Tensile Modulus along X- 34300
direction Ex, MPa
2
Tensile Strength of the 900
material, MPa
3
Compressive Strength of 450
the material, MPa
4
Mass density of the 2.6x10-6
material, kg/mm3
5
Flexural Modulus of the 40000
Material, MPa
6
Flexural Strength of the 1200
Material, MPa

FIG1. CATIA MODEL OF FRP LEAF SPRING

3.1 ANALYSIS OF FRP LEAF SPRING.

V. RESULTS AND DISCUSSION

IJSRET @ 2013

International Journal of Scientific Research Engineering & Technology (IJSRET)


Volume 2 Issue2 pp 103-107 May 2013
www.ijsret.org
ISSN 2278 0882

FIG2 NODAL DELECTION IN Z-DIRECTION FOR


FRP LEAF SPRING

FIG5 PRINCIPAL STRESS 2

FIG 6 PRINCIPAL STRESS 3


RESULTS: STEEL LEAF SPRING

FIG3 VON MISES STRESSES FOR FRP LEAF


SPRING

FIG 4 PRINCIPAL STRESS

FIG 7 NODAL DELECTION IN Y-DIRECTION IN


STEEL LEAF SPRING

IJSRET @ 2013

International Journal of Scientific Research Engineering & Technology (IJSRET)


Volume 2 Issue2 pp 103-107 May 2013
www.ijsret.org
ISSN 2278 0882

bottom part of the leaf spring. In the post


processing, the results are viewed. Graphical
display of displacement and stresses are shown in
chapter 7. The main criteria of the design are
obtained, but the structure is safe.
The maximum deflection and maximum stress
are found and it is shown in figures.

FIG 8 STRESS IN THE STEEL LEAF SPRING

Table 1 Maximum Deflection for FRP Spring


S.No Load, N Ux, mm Uy,
Uz,
mm
mm
1
107394 0.1153
1.2
11.047
2
98406
0.1038
1.097
10.122
3
98800
0.1054
1.102
10.162
4
34300
0.03614 0.3831 3.52

VI DISCUSSIONS

Table 2 Maximum Stress for FRP Spring

FRP leaf spring was designed in this work as a


mono leaf constant cross-section area varying
depth with fibers oriented in axial direction. The
stiffness of the leaf spring must be so controlled
that spring deflects to specified values during the
bump ride so that shock will not be transmitted to
the vehicle body. The leaf spring should have
required fatigue strength to withstand the repeated
loads arising due to bumpy ride.
In this project, a procedure for designing a
mono leaf composite leaf spring is formulated
considering the constant cross section area. The
thickness and width at various sections are
calculated. Mono leaf FRP leaf spring is designed
according to the given specifications for a truck.
The three cases taken for calculating maximum
load are:
Case 1: vehicle passing over a bump while
braking.
Case 2: vehicle passing over a bump while
accelerating.
Case 3: vehicle passing over a bump while
cornering.

Which are within the allowable limit.Steel leaf


spring is designed and modeled in ANSYS for the
given specifications. Finite Element Analysis is
taken out in ANSYS using the element BEAM 4
for the maximum load condition with same
boundary conditions. In the post processing results
are viewed and displayed in chapter 7.
Table 3 Maximum Deflection for Steel Spring
S.No Load,
Ux,
Uy,
Theoretical
N
mm
mm
Deflection
1
107394 1.262
9.65
15.53
2
98406
1.156
8.843 14.23
3
98800
1.161
8.878 14.29
4
34300
0.4029 3.082 4.96

The designed FRP leaf spring is modeled in


CATIA V5.
Finite Element Analysis has been done in the
created FRP model, for the maximum load of
107394N. Here we used SOLID 45 element for the
FRP leaf spring. First the leaf is meshed, boundary
conditions are applied by arresting all the degrees
of freedom in the eyes. Loads are applied in the

IJSRET @ 2013

Table 4 Maximum Stress for Steel Spring


S.No Load, N Line
Theoretical
Stress
Stress
N/mm2
1
107394 1247
1242.91
2
98406
1114
1138.95
3
98800
1120
1143.51
4
34300
402.86
396.98

International Journal of Scientific Research Engineering & Technology (IJSRET)


Volume 2 Issue2 pp 103-107 May 2013
www.ijsret.org
ISSN 2278 0882

limit. The weight reduction has greater influence in


noise and vibration characteristics. Glass fibers are for
manufacturing instead of carbon due to low cost. The
results are encouraging and suggest that ANSYS can
be used effectively and efficiently in other complex
and realistic designs often encountered in engineering
applications, where experimental is not possible due to
shortage of time and other constraints.

VIII REFERENCE
1. W.G.GOTTENBERG and K.H.L.O IN THE 38th
Annual Conference, Reinforced Plastics/Composite
Institute, The society of Plastics Industry, inc.
February 7-11, 1983 titled Glass Fiber Reinforced
Epoxy Leaf Spring Design.

Fig 8 Load Vs Deflection Graph

2. JOHN E. MUTZNER and DAVID S.RICHARD


titled Development and Testing of Composite Truck
Trailer Leaf Spring.
3. Concepts and applications of Finite Element
Methods ROBERT D.COCK
4. Introduction to Finite
TIRUPATHI
ASHOK D.BELEGUNDU

Element Methods
CHANDRUPATLA

5. User Hand Book of ANSYS.


Fig 9 Load Vs Stress Graph
Both the FRP and steel leaf spring are designed and
modeled and results are compared:
Weight of steel leaf spring = 347kg
Weight of FRP leaf spring = 196kg
Amount of weight saving
=
43.5%
Max. stress in steel leaf spring= 1247N/mm.
Max. stress in FRP leaf spring=
158.23N/mm.

6. Introduction to Composite MaterialAUTAR


K.KAW

VII CONCLUSION & FUTURE SCOPE


A procedure to design a composite leaf spring
has been established. Leaf spring made up of EGlass/Epoxy multi layered composites has been
designed. FRP and steel models are created in ANSYS.
The Finite Element Modeling presented in the analysis
is able to predict the stress distribution.
When maximum load is applied on the steel leaf
spring, the maximum stress is greater than that of FRP
leaf spring. Even under the maximum load, the
maximum stress in the FRP is within the allowable

IJSRET @ 2013

You might also like