A Project Presentation

On
Design, Analysis and Fabrication of Leaf Spring

Under Guidance of
Mr. Arun Sharma

By:
Vijay Kumar Chauhan
Vipin Sahai Pankaj
Virendra Pratap Singh
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The aim of our project is to understand fabrication
process, designing process and working of a Leaf
Spring under practical conditions. And prepare a
prototype model of a Leaf Spring.

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Spring
A spring is defined as an elastic body, whose function is to distort when
loaded and to recover its original shape when the load is removed. The
various important applications of springs are as follows:

1. To caution, absorb or control energy due to either shock or

vibration as in car springs, railways buffers etc.

2. To apply forces as in brakes, clutches and spring loaded valves

3. To control motion by maintaining contact between two elements

as in cams and followers

4. To measure forces as in spring balances, engine indicators.

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Types of Spring
1.Helical Spring

2.Conical and volute Spring

3.Torsion Spring

4.Laminated or leaf Spring

5. Clock spring

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Leaf Spring:
 Leaf springs are widely used for automobile and rail road suspensions.

 It consists of a series of flat plates, usually of semi- elliptical shape.

 The leaves are held together by means of two U-bolts and a centre clip.

 The longest leaf, called the master leaf, is bent at both ends to form the spring
eye.

 At the center, the spring is fixed to the axle of the car. Multi- leaf springs are
provided with one or two extra full length leaves in addition to the master leaf.

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 Advantages and Disadvantages of Leaf Springs
 In terms of function, leaf spring suspensions are much simple.

 Leaf springs are also much sturdier, and are capable of handling much higher
loads with less deflection than coils.

 The two main drawbacks to a coil spring suspension are cost and load-
bearing.

Coil spring suspensions offer more range of suspension movement, and allow
the user a wider tuning envelope through the suspension range than leaf
springs.

These springs also flex a great deal less than coil springs, resulting in a loss of
wheel-to-ground contact under extreme conditions.

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Construction Of Leaf Spring:

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 The different types of manufacturing process involved
are:
1. Shearing of flat bar
2. End Heating process forming (hot & cold process)

3. Heat treatment

4. Surface preparation

5. Eye bush preparation process

6. Assembly
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 Material Used for Leaf Spring :
The materials used for leaf springs is usually a plain carbon steel having
0.90 to 1.0% carbon.

According to Indian Standards the Recommended Materials are:

 For Automobiles:

 50 Cr 1 ,

 50 Cr 1 V 23 ,

 55 Si 2 Mn 90

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COMPOSITE CARBON FIBRE LEAF SPRING:

Now-a-days industries are trying to reduce the weight and increase the
strength of leaf spring for efficient suspension.

Composite carbon fiber is the best material suitable for the above
required criteria.

This material has less weight and high strength when compared to the

materials using in the leaf springs using in nowadays leaf springs.

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Static test of composite mono Leaf Spring

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Static load test for maximum deflection

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How a Leaf Spring works in Automobiles??

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 Conclusion
During this presentation we can conclude that Leaf Spring prefers over other
types of springs because it consists following characteristics:
1. Construction is very simple.
2. Prefer for heavy load vehicles.
3. Definite path of motion under active condition.
4. Higher strength as compare to other type of springs.

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Thank you

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