Design and Analysis of Leaf Spring
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IJSRSET1841302 | Received : 11 Feb 2018 | Accepted : 21 Feb 2018 | January-February-2018 [(4) 1 : 962-966]
© 2018 IJSRSET | Volume 4 | Issue 1 | Print ISSN: 2395-1990 | Online ISSN : 2394-4099
Themed Section : Engineering and Technology
109
Design and Analysis of Leaf Spring
Saurabh S. Rodge1, Tushar P. Patil1, Pavan Nikam2
1Student, Vishwatmak Om Gurudev College of Engineering, Shahapur, Maharashtra, India
2Professor, Vishwatmak Om Gurudev College of Engineering, Shahapur, Maharashtra, India
ABSTRACT
We know that the spring plays very essential part of every automobile for suspension point of view. Leaf spring
is the main type of suspension system which is used in many light and heavy vehicles. Leaf spring used in many
vehicles due to having some main characteristics which are shown below.
1. Uniformly load distribution
2. Lower cost
3. Rough used
4. Easier in Isolation and Tightly attached with working frame
Today every automobile company has been working on increasing the efficiency with reducing the weight
without having any load carrying capacity. In this paper we would like to review some previous research work
performed on the leaf spring by previous researchers for increasing the working condition and capacity with
load reduction. The paper based on material composition, experimental testing and load (Steady, Dynamic)
study etc.
Key words: Leaf Spring, Material Compositions, Mathematics, Experiments, ANSYS
I. INTRODUCTION
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. Leaf springs absorb
the vehicle vibrations, shocks and bump loads
(induced due to road irregularities) by means of
spring deflections, so that the potential energy is
stored in the leaf spring and then relieved slowly.
Ability to store and absorb more amount of strain
energy ensures the comfortable suspension system.
Semi-elliptic leaf springs are almost universally used
for suspension in light and heavy commercial
vehicles. For cars also, these are widely used in rear
suspension. The spring consists of a number of leaves
called blades. The blades are varying in length. The
blades are us 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. Springs are an important and frequently used
component in mechanical engineering. Whilst most
people are able to recognize a few standard spring
configurations, the range of springs is actually much
broader: they have many different forms and perform
a number of quite separate and distinct functions,
with one spring often combining several functions.
The spring is mounted on the axle of the vehicle. The
entire vehicle load rests on the leaf spring. The front
end of the spring is connected to the frame with a
simple pin joint, while the rear end of the spring is
connected with a shackle. Shackle is the flexible link
which connects between leaf spring rear eye and
frame. When the vehicle comes across a projection on
the road surface, the wheel moves up, leading to
deflection of spring. This changes the length between
© 2018 IJSRSET | Volume 4 | Issue 1 | Print ISSN: 2395-1990 | Online ISSN : 2394-4099
Themed Section : Engineering and Technology
109
Design and Analysis of Leaf Spring
Saurabh S. Rodge1, Tushar P. Patil1, Pavan Nikam2
1Student, Vishwatmak Om Gurudev College of Engineering, Shahapur, Maharashtra, India
2Professor, Vishwatmak Om Gurudev College of Engineering, Shahapur, Maharashtra, India
ABSTRACT
We know that the spring plays very essential part of every automobile for suspension point of view. Leaf spring
is the main type of suspension system which is used in many light and heavy vehicles. Leaf spring used in many
vehicles due to having some main characteristics which are shown below.
1. Uniformly load distribution
2. Lower cost
3. Rough used
4. Easier in Isolation and Tightly attached with working frame
Today every automobile company has been working on increasing the efficiency with reducing the weight
without having any load carrying capacity. In this paper we would like to review some previous research work
performed on the leaf spring by previous researchers for increasing the working condition and capacity with
load reduction. The paper based on material composition, experimental testing and load (Steady, Dynamic)
study etc.
Key words: Leaf Spring, Material Compositions, Mathematics, Experiments, ANSYS
I. INTRODUCTION
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. Leaf springs absorb
the vehicle vibrations, shocks and bump loads
(induced due to road irregularities) by means of
spring deflections, so that the potential energy is
stored in the leaf spring and then relieved slowly.
Ability to store and absorb more amount of strain
energy ensures the comfortable suspension system.
Semi-elliptic leaf springs are almost universally used
for suspension in light and heavy commercial
vehicles. For cars also, these are widely used in rear
suspension. The spring consists of a number of leaves
called blades. The blades are varying in length. The
blades are us 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. Springs are an important and frequently used
component in mechanical engineering. Whilst most
people are able to recognize a few standard spring
configurations, the range of springs is actually much
broader: they have many different forms and perform
a number of quite separate and distinct functions,
with one spring often combining several functions.
The spring is mounted on the axle of the vehicle. The
entire vehicle load rests on the leaf spring. The front
end of the spring is connected to the frame with a
simple pin joint, while the rear end of the spring is
connected with a shackle. Shackle is the flexible link
which connects between leaf spring rear eye and
frame. When the vehicle comes across a projection on
the road surface, the wheel moves up, leading to
deflection of spring. This changes the length between
International Journal of Scientific Research in Science, Engineering and Technology (ijsrset.com) 110
the spring eyes. If both the ends are fixed, the spring
will not be able to accommodate this change of
length. So, to accommodate this change in length
shackle is provided at one end, which gives a flexible
connection. The front eye of the leaf spring is
constrained in all the directions, where as rear eye is
not constrained in X-direction. This rare eye is
connected to the shackle. During loading the spring
deflects and moves in the direction perpendicular to
the load applied. When the leaf spring deflects, the
upper side of each leaf tips slides or rubs against the
lower side of the leaf above it. This produces some
damping which reduces spring vibrations, but since
this available damping may change with time, it is
preferred not to avail of the same. Moreover, it
produces squeaking sound. Further if moisture is also
present, such inter - leaf friction will cause fretting
corrosion which decreases the fatigue Strength of the
spring.
II. LITERATURE REVIEW
In this section research papers are discussed related to
the present work. Published papers are highlight in
this section.
1) Mahmood M. shokrieh and Davood Rezaei
presented work on design, analysis and optimization
of leaf spring .The aim of this review paper was steel
leaf spring was replaced with an optimized composite
one. Main objective of this paper was to obtain a
spring with minimum weight that is capable of
carrying given static external forces without failure.
Here the work is carried out of a four-leaf steel spring
which used in the rear suspension system of light
vehicles & heavy duty vehicles. The four-leaf steel
spring is analyzed by using ANSYS V5.4 software.
The finite element results showing stresses and
deflections verified the existing analytical and
experimental solutions. Using the results of the steel
leaf spring, a composite one made from fiberglass
with epoxy resin is designed and optimized using
ANSYS. Main consideration is given to the
optimization of the spring geometry. In this study
stress and displacements were used as design
constraint. The experimental results are verified with
the analytical data and the finite element solutions for
the same dimensions. Result shows that stresses in the
composite leaf spring are much lower than that of the
steel leaf spring. Compared to the steel leaf spring the
optimized composite leaf spring without eye units
weights nearly 80% less than the steel spring. The
natural frequency of composite leaf spring is higher
than that of the steel leaf spring and is far enough
from the road frequency to avoid the resonance.
2) E. Mahdi a, O.M.S. Alkoles et al. presented work
on light composite elliptic springs for vehicle
suspension. They worked on based study marries
between an elliptical configuration and the woven
roving composites. In this paper, the influence of
ellipticity ratio on performance of woven roving
wrapped composite elliptical springs has been
investigated both experimentally and numerically. A
series of experiments was conducted for composite
elliptical springs with ellipticity ratios (a/b) ranging
from one to two. Here they were also presented
history of their failure mechanism. Both spring rate
and maximum failure increase with increasing wall
thickness. In general, this present investigation
demonstrated that composites elliptical spring can be
used for light and heavy trucks and meet the
requirements, together with substantial weight saving.
The results showed that the ellipticity ratio
significantly influenced the spring rate and failure
loads. Composite elliptic spring with ellipticity ratios
of a/b 2.0 displayed the highest spring rate.
3) Y. N. V. Santhosh Kumar, M. Vimal Teja et. al
presented work on design and analysis of composite
leaf spring . They also discussed the advantages of
composite material like higher specific stiffness and
strength, higher strength to weight ratio. This work
deals with the replacement of conventional steel leaf
spring with a Mono Composite leaf spring using E-
Glass/Epoxy. For this they selected design parameters
and analysis of it. Main objective of this work is
minimizing weight of the composite leaf spring as
compared to the steel leaf spring. For this they
the spring eyes. If both the ends are fixed, the spring
will not be able to accommodate this change of
length. So, to accommodate this change in length
shackle is provided at one end, which gives a flexible
connection. The front eye of the leaf spring is
constrained in all the directions, where as rear eye is
not constrained in X-direction. This rare eye is
connected to the shackle. During loading the spring
deflects and moves in the direction perpendicular to
the load applied. When the leaf spring deflects, the
upper side of each leaf tips slides or rubs against the
lower side of the leaf above it. This produces some
damping which reduces spring vibrations, but since
this available damping may change with time, it is
preferred not to avail of the same. Moreover, it
produces squeaking sound. Further if moisture is also
present, such inter - leaf friction will cause fretting
corrosion which decreases the fatigue Strength of the
spring.
II. LITERATURE REVIEW
In this section research papers are discussed related to
the present work. Published papers are highlight in
this section.
1) Mahmood M. shokrieh and Davood Rezaei
presented work on design, analysis and optimization
of leaf spring .The aim of this review paper was steel
leaf spring was replaced with an optimized composite
one. Main objective of this paper was to obtain a
spring with minimum weight that is capable of
carrying given static external forces without failure.
Here the work is carried out of a four-leaf steel spring
which used in the rear suspension system of light
vehicles & heavy duty vehicles. The four-leaf steel
spring is analyzed by using ANSYS V5.4 software.
The finite element results showing stresses and
deflections verified the existing analytical and
experimental solutions. Using the results of the steel
leaf spring, a composite one made from fiberglass
with epoxy resin is designed and optimized using
ANSYS. Main consideration is given to the
optimization of the spring geometry. In this study
stress and displacements were used as design
constraint. The experimental results are verified with
the analytical data and the finite element solutions for
the same dimensions. Result shows that stresses in the
composite leaf spring are much lower than that of the
steel leaf spring. Compared to the steel leaf spring the
optimized composite leaf spring without eye units
weights nearly 80% less than the steel spring. The
natural frequency of composite leaf spring is higher
than that of the steel leaf spring and is far enough
from the road frequency to avoid the resonance.
2) E. Mahdi a, O.M.S. Alkoles et al. presented work
on light composite elliptic springs for vehicle
suspension. They worked on based study marries
between an elliptical configuration and the woven
roving composites. In this paper, the influence of
ellipticity ratio on performance of woven roving
wrapped composite elliptical springs has been
investigated both experimentally and numerically. A
series of experiments was conducted for composite
elliptical springs with ellipticity ratios (a/b) ranging
from one to two. Here they were also presented
history of their failure mechanism. Both spring rate
and maximum failure increase with increasing wall
thickness. In general, this present investigation
demonstrated that composites elliptical spring can be
used for light and heavy trucks and meet the
requirements, together with substantial weight saving.
The results showed that the ellipticity ratio
significantly influenced the spring rate and failure
loads. Composite elliptic spring with ellipticity ratios
of a/b 2.0 displayed the highest spring rate.
3) Y. N. V. Santhosh Kumar, M. Vimal Teja et. al
presented work on design and analysis of composite
leaf spring . They also discussed the advantages of
composite material like higher specific stiffness and
strength, higher strength to weight ratio. This work
deals with the replacement of conventional steel leaf
spring with a Mono Composite leaf spring using E-
Glass/Epoxy. For this they selected design parameters
and analysis of it. Main objective of this work is
minimizing weight of the composite leaf spring as
compared to the steel leaf spring. For this they
International Journal of Scientific Research in Science, Engineering and Technology (ijsrset.com) 111
selected the composite material was E-Glass/Epoxy.
The leaf spring was modeled in Pro/E and the analysis
was done using ANSYS Metaphysics. From results
they observed that the composite leaf spring weighed
only 39.4% of the steel leaf spring for the analyzed
stresses. So from result they proved that weight
reduction obtained by using composite leaf spring as
compared to steel was 60.48 %, and it was also proved
that all the stresses in the leaf spring were well within
the allowable limits and with good factor of safety. It
was found that the longitudinal orientations of fibers
in the laminate offered good strength to the leaf
spring.
4) Pankaj Saini, Ashish Goel, Dushyant Kumar et al.
studied on design and analysis of composite leaf
spring for light vehicles. Main objective of this work
is to compare the stresses and weight saving of
composite leaf spring with that of steel leaf spring.
Here the three materials selected which are glass fiber
reinforced polymer(E glass/epoxy),carbon epoxy and
graphite epoxy is used against conventional steel. The
design parameters were selected and analyzed with
the steel leaf sprin From results, they observed the
replacement of steel with optimally designed
composite leaf spring can provide 92% weight
reduction and also the composite leaf spring has lower
stresses compared to steel spring.. From the static
analysis results it is found that there is a maximum
displacement of in the steel leaf spring. From the
result, among the three composite leaf springs, only
graphite/epoxy composite leaf spring has higher
stresses than the steel leaf spring. From results its
proved that composite mono leaf spring reduces the
weight by 81.22% for E-Glass/Epoxy, 91.95% for
Graphite/Epoxy, and 90.51 % for Carbon/Epoxy over
steel leaf spring. Hence it is concluded that E-
glass/epoxy composite leaf spring can be suggested for
replacing the steel leaf spring from stress and stiffness
point of view.
5) Manas Patnaik, Narendra Yadav, et al worked on
study of a parabolic leaf spring by finite element
method & design of experiments. Main objective of
this study was the behavior of parabolic leaf spring,
design of experiment has been implemented. For
DOE, they selected input parameters such as Eye
Distance & Depth of camber. This work is carried out
on a mono parabolic leaf spring of a mini loader truck,
which has a loading capacity of 1 Tonnes. The
modelling of the leaf spring has been done in SOLID
WORK V5 R20. Max Von Mises stress and Max
Displacement are the output parameters of this
analysis. In DOE Eye Distance & Depth of camber
have been varied and their affect on output
parameters have been plotted. The variation of
bending stress and displacement values are computed.
From design of experiments they observed following
a) If the camber is increased there is a decrease in the
average amount of displacement.
b) If the eye distance is increased there is an increase
in the average amount of displacement.
c) If the camber is increased there is an increase in the
average amount of von misses stress.
d) If the eye distance is increased there is an increase
in the average amount on von misses stress. Hence
from results it is conclude that the optimum setting of
dimensions pertaining to parabolic leaf spring can be
achieved by studying the various plots obtained from
Design of Experiments.
6) Malaga. Anil Kuma, T. N. Charyulu, et al.
presented work on design optimization of leaf spring.
The automobile industry has shown increased interest
in the replacement of steel spring with composite leaf
spring. Main purpose of this paper is to replace the
multi-leaf steel spring by mono composite leaf spring
for the same load carrying capacity and
stiffness.Composite materials have more elastic strain
energy storage capacity and high strength-to-weight
ratio as compared to those of steel. It is possible to
reduce the weight of the leaf spring without any
reduction on load carrying capacity and stiffness. The
design constraints were limiting stresses and
displacement. Here the dimensions of a leaf spring of
a light weight vehicle are chosen and modeled using
ANSYS 14. As the leaf spring is symmetrical about the
axis, only half part of the spring is modeled by
selected the composite material was E-Glass/Epoxy.
The leaf spring was modeled in Pro/E and the analysis
was done using ANSYS Metaphysics. From results
they observed that the composite leaf spring weighed
only 39.4% of the steel leaf spring for the analyzed
stresses. So from result they proved that weight
reduction obtained by using composite leaf spring as
compared to steel was 60.48 %, and it was also proved
that all the stresses in the leaf spring were well within
the allowable limits and with good factor of safety. It
was found that the longitudinal orientations of fibers
in the laminate offered good strength to the leaf
spring.
4) Pankaj Saini, Ashish Goel, Dushyant Kumar et al.
studied on design and analysis of composite leaf
spring for light vehicles. Main objective of this work
is to compare the stresses and weight saving of
composite leaf spring with that of steel leaf spring.
Here the three materials selected which are glass fiber
reinforced polymer(E glass/epoxy),carbon epoxy and
graphite epoxy is used against conventional steel. The
design parameters were selected and analyzed with
the steel leaf sprin From results, they observed the
replacement of steel with optimally designed
composite leaf spring can provide 92% weight
reduction and also the composite leaf spring has lower
stresses compared to steel spring.. From the static
analysis results it is found that there is a maximum
displacement of in the steel leaf spring. From the
result, among the three composite leaf springs, only
graphite/epoxy composite leaf spring has higher
stresses than the steel leaf spring. From results its
proved that composite mono leaf spring reduces the
weight by 81.22% for E-Glass/Epoxy, 91.95% for
Graphite/Epoxy, and 90.51 % for Carbon/Epoxy over
steel leaf spring. Hence it is concluded that E-
glass/epoxy composite leaf spring can be suggested for
replacing the steel leaf spring from stress and stiffness
point of view.
5) Manas Patnaik, Narendra Yadav, et al worked on
study of a parabolic leaf spring by finite element
method & design of experiments. Main objective of
this study was the behavior of parabolic leaf spring,
design of experiment has been implemented. For
DOE, they selected input parameters such as Eye
Distance & Depth of camber. This work is carried out
on a mono parabolic leaf spring of a mini loader truck,
which has a loading capacity of 1 Tonnes. The
modelling of the leaf spring has been done in SOLID
WORK V5 R20. Max Von Mises stress and Max
Displacement are the output parameters of this
analysis. In DOE Eye Distance & Depth of camber
have been varied and their affect on output
parameters have been plotted. The variation of
bending stress and displacement values are computed.
From design of experiments they observed following
a) If the camber is increased there is a decrease in the
average amount of displacement.
b) If the eye distance is increased there is an increase
in the average amount of displacement.
c) If the camber is increased there is an increase in the
average amount of von misses stress.
d) If the eye distance is increased there is an increase
in the average amount on von misses stress. Hence
from results it is conclude that the optimum setting of
dimensions pertaining to parabolic leaf spring can be
achieved by studying the various plots obtained from
Design of Experiments.
6) Malaga. Anil Kuma, T. N. Charyulu, et al.
presented work on design optimization of leaf spring.
The automobile industry has shown increased interest
in the replacement of steel spring with composite leaf
spring. Main purpose of this paper is to replace the
multi-leaf steel spring by mono composite leaf spring
for the same load carrying capacity and
stiffness.Composite materials have more elastic strain
energy storage capacity and high strength-to-weight
ratio as compared to those of steel. It is possible to
reduce the weight of the leaf spring without any
reduction on load carrying capacity and stiffness. The
design constraints were limiting stresses and
displacement. Here the dimensions of a leaf spring of
a light weight vehicle are chosen and modeled using
ANSYS 14. As the leaf spring is symmetrical about the
axis, only half part of the spring is modeled by
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