TABLE OF CONTENT Sr.No. TITLE Introduction Material Selection ‘Mesh Model Result Page No.LIST OF TABLES Table No. TITLE Page No. i High Carbon 7 Steel(SAE1074) Properties 4 Mesh Details. 1 3 Results From FEA 15 LIST OF FIGURES Fig No. TITLE, Page No. 1 Leaf Spring 5 2 Model 6 3 Connections 10 4 Meshing 10 ta Meshing Details in 5 Boundary Condition 1 12 6 Boundary Condition 2 BB. 7 Displacement 13 8 Force 14 9 Total Deformation 15 10 Equivalent (von-Misses) 16 Stress 1 Equivalent Elastic Strain 17 12 Strain Energy 181. Abstract Leaf springs are used in suspension systems. The industry has shown increased interest in the designing of Leaf springs. Leaf springs are designed as generalized force elements where the position, velocity and orientation of the axle mounting gives the reaction forces in the chassis attachment positions. The past literature survey shows that leaf springs are designed as generalized force elements where the position, velocity and orientation of the axle mounting gives the reaction forces in the chassis attachment positions. Therefore, analysis of the composite material becomes equally important to study the behaviour. The leaf springs are modeled with ANSYS Design Modeler and the analysis is carried out using ANSYS 16 FEA software to predict the behaviour. The purpose of the project is to perform analysis of leaf spring for Test of * Total deformation + Equivalent von misses stress + Equivalent elastic strain + Strain energy Ata load of 5000 N using ANSYS 16 Workbench .2. Introduction A spring is defined as an elastic body, whose function is to distort when loaded and to recovers its original shape when the load is removed. Originally Leaf Spring called laminated or carriage spring, a leaf spring is a simple form of spring, commonly used for the suspension in wheeled vehicles. Leaf springs are mainly used in suspension Systems to absorb shock loads in automobiles like light Motor vehicles, heavy duty trucks and in rail systems. The spring consists of a number of leaves called blades. The blades are varying in length. The blades are usually given an initial curvature or cambered so that they will tend to straighten under the load. The leaf spring is based upon the theory of a Beam of uniform strength. The lengthiest blade has eyes on its ends. This blade is called main or master leaf, the remaining blades are called graduated leaves. All the blades are bound together by means of steel straps. fe2-_—_—@§. —=—sdreiet ————___al eye camber i == master leaf pS central clamp rebound clip graduated leaves Fig No.1 Leaf Spring Construction of leaf spring: * Leaf springs used in automobiles is of Semi-Elliptical in form. It is built up of number of plates (known as leaf), which are of reducing lengths. * The longest leaf is called main leaf or Master leaf, and the other leaves are called as graduated leaves. * The spring is clamped to the axle by means of U-bolts. Rebound clips are used to hold the leaves together. © Central clamp is used to fix the position of leaf spring to the wheel axle.3. Design Of Leaf Spring The aim of this work is to develop a 3D modelling of leaf spring and to study the Leaf springs functionality, design parameters effecting on a automobile vehicle suspension system. Leaf springs are made out of flat plates. The advantage of leaf spring over helical spring is that the ends of the spring may be guided along a definite path as it deflects to act as a structural member in addition to energy absorbing device. Thus the leaf springs may carry lateral loads, brake torque, driving torque ete., in addition to shocks. Consider a single plate fixed at one end and loaded at the other end. This plate may be used as.a flat spring. Let = Thickness of plate, b= Width of plate, and L= Length of plate or distance of the load W from the cantilever end. M W.L 6WL 7 “oe gx be Wit wat awa _ 2a? On Get "SEDO Al” Eb BEE EL, —— ar fom = Nigh? and Ben END bE Where, constants p and q are given as, For simply supported beam: p= 3 & q= 3 For Cantilever beam: p= 6 & q= 6 N= Number of plates, Leaf spring modelling in Creo 3.0 Dimensions: Length of top layer= 91 mm, Bottom layer = 26 mm, Decrease in length of each layer is 5 mm, Total layers = 6. ow en 94670 Fig No.2 Model4. Material Selection Material used is high carbon steel (SAE1074) SAE1074 steel is a carbon (non-alloy) steel formulated for primary forming into wrought products. 1074 is the designation in both the SAE and AISI systems for this material. It can have a moderately low ductility and a fairly high tensile strength among wrought carbon or non-alloy steels. It has the highest hardness and toughness of the carbon steels and the lowest ductility. It is used in cutting tools, springs high strength wire and dies. Table No.1 Material/Physical High carbon steel(SAE1 Properties 074) Densit 7846-006 kgm? ‘Young's Modulus 7.1e+005 Shear modulus 2.7519e+005 Poisson’ ratio 0.29 Thermal conductivity 498-002 W mm*1C™15, Finite Element Analysis Of Leaf Spring Engineering analysis can be broadly divided into two categories: classical methods and numerical methods. Following tree diagram shows various methods for solving engineering problems. As shown below, the finite element method is one of several methods for solving engineering problems. Engineering analysi ClassicalMethods Numerical Methods Closed form [ Finite Element | Approximate Finite Difference Finite volume Boundary element A. Analysis Methods * Closed-form solutions are available for simple problems such as bending of beams and torsion of prismatic bars Approximate methods using series solutions to governing differential equations are used to analyze more complex structures such as plates and shells The classical methods can only be used for structural problems with relatively simple geometry, loading, and boundary conditions. B. Numerical methods Numerical methods address a broad range of problems. * Boundary Element Method: Solves the governing differential equation for the problem with integral equations over the boundary of the domain. Only the boundary surface is meshed with elements. * Finite Difference Method: Replaces governing differential equations and boundary conditions with corresponding algebraic finite difference equations. * Finite Element Method (FEM)a) Capable of solving large, complex problems with general geometry, loading, and boundary conditions b) Increasingly becoming the primary analysis tool for designers and analysts ©) The Finite Element Method is also known as the Matrix Method of Structural Analysis in the literature because it uses matrix algebra to solve the system of simultaneous equations.6. Mesh Model Leaf spring is meshed using solid element type and has the shapes of tetrahedral. The Mesh consist of 58995 Nodes, 31657 Elements and element size I mm. All the connections of the Leaf Spring are bonded. rs Fig No. 3 Connections Fig No. 4 Meshing 10Nodes Elements 31657 Mesh Metric [None ¥ Fig No 4a Meshing Details Table No.2 Mesh Type Coarse Mesh Element Type Tetrahedral No. of Nodes 58995 No. of Elements 31657 uw7, Boundary Conditions For this static structural analysis the following boundary conditions are applied. Fixed remote displacements at two sides of eye locations Fig No. 6 and Fig No. 7 . Displacement at the centre position X and Z. axis 0 Y axis free Fig No. 8. Force at the centre 50000 N on Y axis in upward direction Fig No. 9. Fig No. 5 Remote displacement 1 12Fig No. 6 Remote displacement 2 Fig No. 7 Displacement 138. Result After applying the given boundary conditions the following Maximum and Minimum, conditions were obtained. Table No. 3a Total deformation Maximum | Minimum | Maximum | Minimum’ occurs on | occurs on Oai74s | 5.77590. | Pan& Part 1 mm 002 mm, 0.00 40,00¢mm) a ———" 20.00 Fig No. 9 Total Deformation Table No. 3b Equivalent (von-Mises) Stress Maximum | Minimum | Maximum | Minimum) occurs on | occurs on 11647 MPa | 1.0613 Part Part & MPa 150.00 20,00 .40,00¢mm) Fig No. 10 Equivalent (von-Mises) Stress ma Table No. 3¢ Equivalent Elastic Strain Maximum | Minimum | Maximum | Minimum’ occurs on | occurs on 1.7094e- | 5.3067e- | Part? Part & 002 006 mm/mm_|_mm/mm 165.3067e-6 Min 20.00 40,00¢mm) Fig No. 11 Equivalent Elastic Strain Table No. 3d Strain Energy Maximum | Minimum | Maximum | Minimum occurs on | occurs on 773 | 15953e- [Part Par 8 mi | 006 mJ 70.00 40,00¢mm) a ————<$<$—$_—_— 20.00 Fig No. 12 Strain Energy 189. Conclusion ‘The leaf spring has been modelled and analysed using ANSYS FEA Software. By performing static analysis it is concluded that the maximum safe load is 50000 N for the given specification of the leaf spring. These static analysis results of 6 layered laminated leaf springs of high carbon steel. The maximum and minimum conditions are obtained. 19