1

MEHRAN UNIVERSITY OF ENGINEERING

AND TECHNOLOGY,JAMSHORO
STRUCTURAL ANALYSIS OF STEEL LEAF WITH HYBRID
LEAF SPRING
GROUP MEMBERS

ASFANDYAR TALPUR (G.L) F16ME38

FAWAD HUSSAIN F16ME150
SAQLAIN RAZA F16ME17

SUPERVIOSED BY
ENGR. MUHAMMAD SHARIF JAMALI 2
Outline

 Introduction
 Literature review
 Problem Statement
 Aims and Objectives
 Methodology
 Assumptions
 Material Selection
 3D modeling and Simulation
 Weight Calculations
 Error
 Results and Observations
 Conclusion
 Future Suggestions
 References

3
Introduction Cont..

LEAF SPRING:

 It is usually made out of flat plates and is also known as flat spring
 Distort when it is loaded and recover its original shape when the load is
removed from it
 Absorbs shock or vibrations produced in vehicles
( [1] , [2] )

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Introduction Cont..
 TYPES OF LEAF SPRING
FOLLOWING ARE TWO TYPES [3]

 Multi Leaf spring

 Mono leaf spring

 SHAPES OF LEAF SPRING

FOLLOWING SHAPES EXISTS[3]

1. Semi Elliptical

2. Elliptical

3. Quarter Elliptical

4. Transverse
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Introduction Cont..

 HYBRID LEAF SPRING

“Leaf spring whose leaves or plates are of different material is called hybrid
leaf spring “

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Introduction Cont..
CONSTRUCTION OF LEAF SPRING

 Longest leaf is known as main leaf or master leaf

 Ends of master leaf formed in the shape of an eye through which the bolts are passed to provide

support
 Other leaves of spring are known to be graduated leaves
 Distance between centre of eye to other eye is known as span or span length
 Distance from centre position of master leaf to the span length is known as camber
 Rebound clips are situated so other leaves share the stress induced in main leaf

([1],[2] )

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8
 Literature Review

S.No Title Authors Year Work

1 Failure assessment Y.S. Kong a , S. 2016 The stress of four different

of leaf spring eye Abdullah a,b , M.Z. spring eye design were
design under Omar a,b,* , S.M. obtained and compared the
various load cases Haris a,b results with material yield and
ultimate tensile strength to
evaluate the sustainability of
spring eye under extreme load
cases. [4]

2 Optimization of Krishan kumara*, 2017 Prepared Computer program

various design M.L.Aggarwalb using the visual basics to
parameters for predict the fatigue life,
EN45A flat leaf thickness and weight of EN45A
spring steel leaf spring on the basis of
stress approach.[5]

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 Literature Review Cont. .

S.No. Title Authors Year Work

3 Design of leaf 1
May Mya Darli Cho, 2017 Analyzed the leaf spring
spring for solar 2
Htay Htay Win, 3Aung design models of various
vehicle car Ko Latt thicknesses for steel using
ANSYS software and
suggested the suitable
thickness for leaf spring of
solar vehicle.[6]

4 Analysis of leaf Jenarthanan M.P*, 2017 Proposed Carbon/Glass

spring using Ramesh Kumar.S, Epoxy Composite as leaf
Carbon/Glass Venkatesh.G, spring material and
epoxy and EN45 Nishanthan.S compared the analytical
using ASYS : A results of stress and
comparison deformation with EN45 Steel
.[7]

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 Literature Review Cont..

S.No Title Authors Year Work

5 Design And SK.Jani Basha1, 2017 Structural Analysis is done on
Optimiztion Of A KLN Murthy2, the leaf spring by using two
Heavy Vechile Leaf Y.Suvarna Kumar3 different materials Mild Steel
Spring By The and Glass Carbon. Modal and
Material E Glass fatigue Analysis is also done
Epoxy And Aluminum Pro/Engineer software is used
Alloy Reinforced With for modeling and ANSYS is
Boron Carbide used for analysis . [8]

6 Stress, Deformation Tasmeen Inteeser 2018 Presented the comparison

and Failure Analysis Khan1, M I Washif between steel leaf spring (AISI
of Parabolic Leaf Rahman Omi2, 1030) and composite
Spring by Finite Md. Jubayer (Carbon/Epoxy) leaf spring
Element Analysis with Hossain3, Md. using CAD models .[9]
Material Optimization Merajul Haque4,
Fazlar Rahman5
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 Literature Review Cont. .

S.No Title Author Year Work

7 Design and Pulkit solankia, 2018 Used structural steel and stainless
computational Ajay Kumar Kavitib steel materials . Output results
analysis of semi- such as deflection, stresses, factor
elliptical and of safety in stress and factor of
parabolic leaf safety in strain term were main
spring focus . Simulation under the
constant load was done with help
of ANSYS 14.0 . [10]

8 Structural and Rohan P Sakale Analyzed the behavior of

Modal Analysis of ,Sharanbassappa fabricated steel and composite leaf
Composite Leaf Patil spring experimental modal testing
Spring and FEA had been carried out and
concluded Composites give better
results . [11]

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 Literature Review Cont..
S.No Title
9 Stress distribution in leaf
spring under variable
parametric and loading
condition
10 Design and static structural
analysis of hybrid leaf
spring using fea
Author Year Work
Jonnala Subha 2018 Static analysis had been
Reddy, performed using ANSYS
M.Bhavani , J. also the natural frequencies
VenataSomiRedy were compared with
excitation frequencies at
variable speed . [12]
Shivkaran Gupta, 2018 Proposed the idea of
PL Verma, Ashish construction of hybrid leaf
Manoria, Sanjay spring a combination of
Jain composite and steel
material leaves on the basis
of practical application and
cost analysis. [13]
13
 Literature Review Cont…

S.No Title Author Year Work

11 Stress analysis of leaf spring Jayesh Sanjay 2019 Found that as result of
suspension system with the Patil combination of leaf spring
combination of helical with helical spring stress
springs reduction to some extent had
been observed.[14]

12 Design and Analysis of Dr J S Suresh1, K 2019 Investigated the suitability of

Steel and Composite
Material leaf Spring
Muneendra2, natural and synthetic fiber
Raffi reinforced hybrid composite
Mohammed3 material to replace existing
synthetic fiber reinforced
composites and compare the
results with steel . [15]

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 Literature Review Cont…

S.No Title Author Year Work

13 Comparative Analysis of M.Tech.Scholar 2019 The material used for
Multi leaf spring and Narendra kumar conventional steel leaf spring
composite leaf spring Verma ,Mukesh was 65Si7 (BIS) and for
using finite element Hemnani,Rakesh composite leaf spring E-
method under static Sharma glass/ Epoxy. Prepared CAD
loading condition models of multi leaf spring
and Analyzed in ANSYS for
stress and deflection . [16]

14 Static and fatigue R.Naresh ,V.B.S. 2019 To obtain the fatigue life of
Analysis of leaf spring Rajendra Prasad , semi-elliptical leaf spring but
with EPDM rubber G.Venkata Rao also deflection , stress ,strain
Sandwhiched between the , and strain energy results
steel leaves using CAD model on
ANSYS. [17]

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Problem Statement

 Currently the automobile industry is working hard to reduce the weight of

the vehicle by replacing the heavy weight components with light weight
components (to save the fuel consumption).

 It is necessary that the light weight components must posses the enough
strength to support the weight of the vehicle without undergoing
maximum stress which may cause failure in components .

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Aims And Objectives

AIM
 Static Structural Analysis of Steel leaf spring compared with hybrid leaf
spring Using ANSYS R15.0 .

OBJECTIVES
1. To develop the 3D model of leaf spring using ANSYS workbench .
2. To perform static structural analysis on Steel leaf spring and Hybrid
Leaf spring
3. To compare the analysis results with the one in Literature
4. To Suggest the best leaf spring for solar vehicle.
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Methodology

Following Methodology Will Be Used To Achieve Our Objectives

Start Material selection for the design

3D modeling on ANSYS Dimensions for the design

Static Structural Analysis Calculations

Results and Discussions Comparison

Conclusion Future Suggestions

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 Material selection
From Literature Review Following Materials Will Be Selected For Our
Design To Achieve Our Objectives

1) Steel (Chromium Steel AISI 5150)[6]

Reason:

 High strength
 Ductility
 Durability
 Withstand heavy loads

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Material Selection

Mechanical Properties of Chromium Steel AISI 5150: [6]

Parameter Value Unit

Density 7850 Kg/m3
Tensile Strength 1620 MPa
Yield strength 1520 MPa
Young’s Modulus 210 GPa
Poison Ratio 0.3 ---

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Material Selection

2) Composite (Hybrid Carbon/Glass Epoxy)

Reason : [13]
 Have Low density
 Good strength to weight ratio
 Resistance to wear
 Control on thermal expansion
 Good abrasion and wear resistance
 lightweight due to low density

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Material Selection

Mechanical Properties of Hybrid Carbon/Glass Epoxy

Composite [7]
Parameter Value Unit
Density 1672 Kg/m3
Tensile Strength 300 MPa
Yield strength 280 MPa
Young’s Modulus 134 GPa
Poison Ratio 0.275 ---

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Dimensions for the Design

 Following Dimensions are taken(Rear leaf Spring Only) [6]

Parameter Value
Thickness 5 mm
Width 45mm
No. of leaves 3
Length of master leaf 680mm
Length of the second leaf 467mm
Length Smallest leaf 360mm
Eye internal diameter 7mm
The radius of the Master leaf 944mm
The radius of the Second leaf 949mm
The radius of the Smallest leaf 954mm 23
3D Modeling on ANSYS

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Static Structural Analysis

 For only steel plates with force 1141.36 N [6] , maximum

stress is shown:

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Static Structural Analysis

 For only steel plates with force 1141.36 N , maximum

deformation is shown:

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Static Structural Analysis

 For only Composite material Plates with force 1141.36 N ,

maximum stress is shown:

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Static Structural Analysis

 For only composite material plates with force 1141.36 N ,

maximum deformation is shown

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 Static Structural Analysis
 For hybrid with central plate of steel and other two of composite
material with force 1141.36 N , maximum stress is shown:

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 Static Structural Analysis
 For hybrid with central plate of steel and other two of composite
material with force 1141.36 N , maximum deformation is shown

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Static Structural Analysis
 For hybrid with central plate of composite material and other two
of steel with force 1141.36 N , maximum stress is shown:

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 Static Structural Analysis
 For hybrid with central plate of composite material and other two of
steel with force 1141.36 N , maximum deformation is shown

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Calculations

The formula for weight in kilogram will be [5] :

Weight = Density * lwt

where (l) is length of each plate, (w) width and (t) thickness of leaf spring
plates which are constant for all three plates . Then the weight of each leaf
spring is shown in table of slide no 36 .

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Calculations

 From [6] , the maximum stress for multi steel leaf spring
under same static loading condition is 662.5 where as in this
research for steel it is 657.3 . So the percentage error in this
work for stress is 0.78% .
 However in [6] analytical results of deformation were not
mentioned as stress and weight reduction was sole purpose

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Results And Observations
Parameter Maximum Maximum Total Weight (kg) % Weight
Equivalent Stress Deformation Reduction

(MPA) (MM)
All three plates of 657.3 9.1554 2.68 ---
Chromium Steel AISI
5150
All three plates of 621.86 12.95 0.5703 78.72 %
Carbon/Glass Epoxy
Composite
Hybrid with Middle 634.07 13.611 1.216 54.62%
plate of Chromium
Steel AISI 5150 and
other two of
Carbon/Glass Epoxy
Hybrid With Middle 643.05 9.7027 2.0126 24.9%
Plate of Carbon/Glass
Epoxy and other two
of Steel

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 Results And Observations
 It has been observed in this work that by changing the material of leaf spring
plates the stress reduces as the deformation increases under same load as can be
seen in the graph .

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Results And Observations

 It can also be seen from graph that the hybrid models have
intermediate results of equivalent stress as of between steel
and composite which can also be seen in [13] .
 However , the deformation is varied by varying the
arrangement of plates of different materials as seen in [13] .
 Weight is also reduced with the use of composites .

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Conclusion

 To sum up , it could be said that by using composite as leaf

spring material can have good results compared to steel .
 Since , composites can replace steel but due to their high cost
[13] it is suggested to use suitable hybrid model to have an
intermediate price having good strength and light weight as
compared to steel and is economically suitable then
Composite leaf spring .

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Future Suggestions

 Comparison with theoretical results to reduce the possibility of

errors as far as possible by taking the help from leaf spring
equations for stress and deformation
 Include central clamps and bolts for nipping and carryout the
static structural analysis
 Use various other advance composite materials for further weight
reduction and load carrying capacity by replacing multi leaves
spring with mono leaf spring.

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Future Suggestions Cont…

 Prediction of Fatigue life of leaf spring before it completely fails

 Analyze the same work with different shapes of leaf spring
 Study the Effects of deflection on strain energy of leaf spring
 Analyze hybrid models with different arrangements of plates on
the basis of material

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 References
[1] G HARINATH GOWD1*, E VENUGOPAL GOUD " STATIC ANALYSIS OF LEAF
SPRING” Vol. 4 No.08 August 2012
[2]R.S khurmi, J.K gupta “Machine design 14th edition “2005
[3] https://sandersonleafsprings.co.uk/different-types-of-leaf-springs/
[4] Y.S. Kong a, S. Abdullah a,b, M.Z. Omar a,b,* , S.M. Harisa,b “Failure assessment of leaf
spring eye design under various load cases” 2016
[5]Krishan kumara*, M.L.Aggarwalb “Optimization of various design parameters for EN45A
flat leaf spring “ 2017
[6] 1MAY MYA DARLI CHO, 2HTAY HTAY WIN, 3AUNG KO LATT “Design and Analysis
of leaf spring for solar vehicle”2017
[7] Jenarthanan M.P*, Ramesh Kumar.S, Venkatesh.G, Nishanthan.S “Analysis of leaf spring
using Carbon/Glass Epoxy and EN45 using ANSYS:Comparision“2017
[8] SK.Jani Basha1, KLN Murthy2, Y.Suvarna Kumar3 "Design and optimization of heavy
vehicle leaf spring by the material E glass epoxy and aluminum alloy reinforced with boron
carbide" 2017
[9] TasmeenInteeser Khan1, M I Washif Rahman Omi2, Md. Jubayer Hossain3, Md. Merajul
Haque4, Fazlar Rahman5 “Stress, Deformation and Failure Analysis of Parabolic Leaf Spring
by Finite Element Analysis with Material Optimization “2018
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 References
[10] Pulkit solankia, Ajay Kumar Kavitib “Design and computational analysis of semi-elliptical
and parabolic leaf spring” 2018
[11] Rohan P Sakale, Sharanbassappa Patil “Structural and Modal Analysis of Composite Leaf
Spring” 2018
[12] Jonnala Subha Reddy, M.Bhavani , J. VenataSomiRedy “Stress distribution in leaf spring
under variable parametric and loading condition” 2018
[13] Shivkaran Gupta, PL Verma, Ashish Manoria, Sanjay Jain “Design and static structural
analysis of hybrid leaf spring using fea” 2018
[14] Jayesh Sanjay Patil “Stress analysis of leaf spring suspension system with the combination
of helical springs” 2018
[15]Dr J S Suresh1, K Muneendra2, Raffi Mohammed3 "To investigate the suitability of natural
and synthetic fiber reinforced hybrid composite material for the purpose of automobile leaf
spring “2019
[16] M.Tech.Scholar Narendra kumar Verma ,Mukesh Hemnani,Rakesh Sharma " Compartive
Analysis of Multi leaf spring and composite leaf spring using finite element method under
static loading condition" 2019
[17] R.Naresh ,V.B.S. Rajendra Prasad , G.Venkata Rao " Static and fatigue Analysis of leaf
spring with EPDM rubber Sandwhiched between the steel leaves " 2019
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