DESIGNING AND ANALYSIS OF

COMPOSITE LEAF SPRING MATERIAL

PRESENTATION BY
MUHAMMED FARIS A V VVT16ME012
AMAL DEV VS VVT16ME006
SAHAD MK VVT16ME014
INTRODUCTION
 In the current scenario, increasing competition and advances in the
automotive industry continue to alter existing products or replace old
products with new ones.
 Modern material is used to optimize energy utilization for all products;
weight reduction has become one of automobile manufactures’ main
focus areas. The use of new material will help to achieve weight
reduction.
 In suspension systems leaf springs are used to absorb shock loads in
automobiles such as light motor vehicles, heavy duty trucks, and rail
systems.
 The use of composite materials for suspension leaf spring decreases the
weight of traditional multi-leaf steel leaf spring by almost 75%.
 This can improve the efficiency of vehicle fuel and riding conditions.
 Natural composite materials have higher elastic strain energy storage ability,
excellent resistance to corrosion, high strength to weight ratio compared to
steel.
 The versatile nature of it makes it suitable for automobiles, railway coach.
 The huge and wide range of natural fiber can reduce the pressure on forest
and agriculture.
 This work is to provide the new idea of fabricating a parabolic leaf spring
plate using natural composite material.
METHODOLOGY
PROBLEM IDENTIFICATION

DATA COLLECTION

DATA ANALYSIS

MODELLING OF LEAF SPRING USING CATIA V5

ANALYSIS OF LEAF SPRING USING ANSYS

RESULT ANALYSIS

COMPARISON

CONCLUSION
LITERATURE REVIEW
 [1]. P saikrishna, 2 s vigneshwaran, 3 ramarajusrinivasara A spring
may be a easy type of spring, commonly used for the suspension in
wheeled vehicles. Leaf springs square measure long and slender plates
hooked up to the frame of a trailer that rest on top of or below the
trailer'saxle. For safe and cozy riding, to stop the road shocks from
being transmitted to the vehicle components and to safeguard the
occupants from road shocks it's necessary to work out the maximum
safe stress and deflection. the target is to realize the stresses and
deformation within the leaf springy applying static load on that.
completely different materials with different mechanical properties
square measure thought about for the structural static analysis. thus
within the present work, spring is meant by considering static load on
vehicle
 [2]Mr. Tharigonda Niranjan Babu *,Mr P. Bhaskar, Mr. S. Moulali In
automobile sector tends to increasing competition and innovation in style
and tends to switch the existing product by new and advanced materials.
Leaf springs area unit special quite springs utilized in automobile
suspension systems. the most operate of spring isn't solely to support
vertical load however conjointly to isolate road induced vibrations. it's
subjected to several load cycles resulting in fatigue failure. The introduction
of composite materials has created it attainable to scale back the burden of
the spring with none reduction in load carrying capacity and stiffness. thus
the target of this paper is to gift a general study on the performance
comparison of composite (E-Glass/Epoxy and Jute E-Glass) spring and
traditional spring. spring is sculptural in CATIA V5R20 package and it's
foreign in ANSYS twelve.0. the traditional composite leaf springs were
analyzed under similar conditions victimization ANSYS package and
therefore the results area unit given. The automobile chassis is mounted on
the axles, not direct however with some style of springs.
 [2] Dev Dutt Dwivedi1, V. K. Jain Design and analysis of composite leaf
spring has been wiped out this paper. ANSYS14.5 has been wont to conduct
the analysis. Static structural tool has been used of ANSYS.A three layer
composite spring with full length leave. E-Glass/epoxy composite material
has been used. typical steel spring results are compared with the gift results
obtained for composite leaf spring. E glass/epoxy material is healthier in
strength and lighter in weight as distinction with conventional steel spring. a
good amount of study has been conducted during this paper to in vestigate
the style and analysis of spring and spring fatigue life.
ANALYSIS OF COMPOSITE LEAF
SPRING (TATA ACE)
DESIGN PART

CONNECTION
PART 1 – Main leaf
PART 2 – Main leaf
PART 3 – Main leaf
PART 4 – Support
PART 1 & PART 2 Are bonded
PART 2 & PART 3 Are bonded
PART 3 & PART 4 Are bonded
FORCE DISTRIBUTION

Kerb Weight = 1000kg

Total Weight = 1600kg
(considering 7 people)
Total Load= 15696
Load distribution to each eye
=15696/8
= 1962N
ANALYSING OF STEEL
Fig 1: Deformation
Fig 2 : Stress
Video 1
ANALYSING OF ALUMINIUM
ALLOY
Fig 3 : Deformation
Fig 4: STRESS
ANALYSING OF EPOXY GLASS UD
Fig 5 : DEFORMATION
Fig 6: STRESS
VIDEO 2
RESULT
CONCLUSION
 The usage of composite materials has resulted in considerable amount
of weight saving when compared to conventional steel leaf spring.
 Taking in to account the weight saving, deformation, shear stress
induced and resultant frequency it is evident that composite has the
most encouraging properties to act as replacement to steel.
 The present work was aimed at modification in suspension system of
the automobiles in particular or any machine by reduction of weight,
which employs leaf spring, in general. This was achieved by reducing
the weight of the leaf spring with the use of composite materials. A part
from being light weight, the use of composites also ensures less noise
and vibration.
 While considering deflection or deformation, maximum deflection
delivered in each material Structural steel= 3.5919mm
Aluminum alloy= 10.113mm
Epoxy glass =88.203mm
 So from that we understood that steel is 3 times larger than aluminum
alloy and around 250% of epoxy glass UD.
 While considering stress delivered in each material
Structural steel =192.41MPa
Aluminum alloy = 193.7MPa
Epoxy glass =195.79MPa
• So maximum stress delivered in each material is almost equal. But while
considering the weight of the leaf comparing with steel, total weight
decreases.
 Even though deflection is high no of leaf increases, as a result deflection
value decreases, stress decreases.
FUTURE SCOPE
 Transient analysis of leaf spring.
 Manufacturing of composite leaf spring.
 Experimental results for composite leaf spring.
 Residual stress calculation using FEA.
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