design & analysis of sandwich composite …...cite this article: shantanu pawar, dr. p. v....

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http://www.iaeme.com/IJMET/index.asp 01 [email protected] International Journal of Mechanical Engineering and Technology (IJMET) Volume 8, Issue 9, September 2017, pp. 01–17, Article ID: IJMET_08_09_001 Available online at http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=8&IType=9 ISSN Print: 0976-6340 and ISSN Online: 0976-6359 © IAEME Publication Scopus Indexed DESIGN & ANALYSIS OF SANDWICH COMPOSITE LEAF SPRING FOR HMV Shantanu Pawar M.Tech, Mechanical Engineering Department, Bharati Vidyapeeth Deemed University College of Engineering, Pune Dr. P. V. Jadhav and Dr. S. S. Chavan Professor, Mechanical Engineering Department, Bharati Vidyapeeth Deemed University College of Engineering, Pune ABSTRACT: Weight reduction with improved strength of design is important research topic all around the globe. One very common solution for this issue now a days are composite material. Leaf springs are important for a suspension of sprung mass in the vehicle; it softens the effect of road vibrations on vehicle. An objective of this work is to reduce the weight of the leaf spring using alternative material for the leaf spring for the application. It will include studying leaf with different composite materials .It is conclude that the Carbon-Glass-Carbon Epoxy Mono Composite Leaf spring shows 91.55 % efficiency analytically to FEA results and 83.04 % efficiency testing results to FEA results. That means it might be allowable for replacement for Steel leaf spring because efficiency is below 20 %. Keywords: Leaf spring, ANSYS 16.2, stress, Composite Material Cite this Article: Shantanu Pawar, Dr. P. V. Jadhav and Dr. S. S. Chavan, Design & Analysis of Sandwich Composite Leaf Spring for Hmv, International Journal of Mechanical Engineering and Technology 8(9), 2017, pp. 01–17. http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=8&IType=9 1. INTRODUCTION Leaf spring was first used in 1804 by Obadiah Elliot for suspending the horse drawn cart. It was then incorporated in early designs of motor vehicles .Weight reduction is termed important in recent times in automobile industry as it saves material as well as energy. Commonly steel leaf springs fail suddenly, which increases possibility of accidents of vehicle due to leaf spring failure. If replaced with fiber reinforced polymer (FRP) leaf springs, the component will fail gradually by layer separation, which is better to reduce chances of accidents due to leaf spring failure. Best technique to reduce weight of the design is to find alternate material, to optimize the shape of the design or to improve manufacturing process used.

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Page 1: DESIGN & ANALYSIS OF SANDWICH COMPOSITE …...Cite this Article: Shantanu Pawar, Dr. P. V. Jadhav and Dr. S. S. Chavan, Design & Analysis of Sandwich Composite Leaf Spring for Hmv,

http://www.iaeme.com/IJMET/index.asp 01 [email protected]

International Journal of Mechanical Engineering and Technology (IJMET) Volume 8, Issue 9, September 2017, pp. 01–17, Article ID: IJMET_08_09_001

Available online at http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=8&IType=9

ISSN Print: 0976-6340 and ISSN Online: 0976-6359

© IAEME Publication Scopus Indexed

DESIGN & ANALYSIS OF SANDWICH

COMPOSITE LEAF SPRING FOR HMV

Shantanu Pawar

M.Tech, Mechanical Engineering Department, Bharati Vidyapeeth Deemed University

College of Engineering, Pune

Dr. P. V. Jadhav and Dr. S. S. Chavan

Professor, Mechanical Engineering Department, Bharati Vidyapeeth Deemed University

College of Engineering, Pune

ABSTRACT:

Weight reduction with improved strength of design is important research topic all

around the globe. One very common solution for this issue now a days are composite

material. Leaf springs are important for a suspension of sprung mass in the vehicle; it

softens the effect of road vibrations on vehicle. An objective of this work is to reduce

the weight of the leaf spring using alternative material for the leaf spring for the

application. It will include studying leaf with different composite materials .It is

conclude that the Carbon-Glass-Carbon Epoxy Mono Composite Leaf spring shows

91.55 % efficiency analytically to FEA results and 83.04 % efficiency testing results to

FEA results. That means it might be allowable for replacement for Steel leaf spring

because efficiency is below 20 %.

Keywords: Leaf spring, ANSYS 16.2, stress, Composite Material

Cite this Article: Shantanu Pawar, Dr. P. V. Jadhav and Dr. S. S. Chavan, Design &

Analysis of Sandwich Composite Leaf Spring for Hmv, International Journal of

Mechanical Engineering and Technology 8(9), 2017, pp. 01–17.

http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=8&IType=9

1. INTRODUCTION

Leaf spring was first used in 1804 by Obadiah Elliot for suspending the horse drawn cart. It

was then incorporated in early designs of motor vehicles .Weight reduction is termed

important in recent times in automobile industry as it saves material as well as energy.

Commonly steel leaf springs fail suddenly, which increases possibility of accidents of vehicle

due to leaf spring failure. If replaced with fiber reinforced polymer (FRP) leaf springs, the

component will fail gradually by layer separation, which is better to reduce chances of

accidents due to leaf spring failure. Best technique to reduce weight of the design is to find

alternate material, to optimize the shape of the design or to improve manufacturing process

used.

Page 2: DESIGN & ANALYSIS OF SANDWICH COMPOSITE …...Cite this Article: Shantanu Pawar, Dr. P. V. Jadhav and Dr. S. S. Chavan, Design & Analysis of Sandwich Composite Leaf Spring for Hmv,

Shantanu Pawar, Dr. P. V. Jadhav and Dr. S. S. Chavan

http://www.iaeme.com/IJMET/index.asp 2 [email protected]

Nearly twenty percent of the un-sprung mass of the vehicle is usually leaf spring

assembly, which makes it attractive option for weight reduction study for the design

improvements. Strain energy can be considered most important criteria for the selection of

design of leaf spring as function of the leaf spring is to store and release the strain energy.

Leaf springs can be classified in to types below

1. Multi-leaf spring

2. Mono-leaf spring

3. Parabolic Single leaf spring

4. Fiber Composite Spring

Most of the leaf springs operate to serve dual purpose, one is to carry load and second is

to control an axle. The spring joined trough bolting tightly to the frame of the vehicle at the

thick end, while the free end is attached to the axel going from a bush. Leaf spring is used in

almost all trucks and light vehicles. It improves the suspension quality and can support heavy

loads. Leaf spring assembly for the rear axle suspension is shown in the figure 1.

Figure 1 Vehicle with leaf spring at rear axle [17]

Leaf spring is installed between the wheels and body of the vehicle, purpose is to isolate

the body from axle partially. This allows axle to move separately. When vehicle is running

over a bad patch of road or speed breaker bumps the wheel movement causes axle to move ,

but body do not experience this movement directly due to leaf spring between them. Leaf

spring is deflected due to this movement and deflection makes leaf spring store strain energy

inside momentarily. This strain energy is then released due to elastic behavior of the material

of leaf spring, which causes spring to oscillate few times before coming to rest at its natural

frequency. This behavior of the leaf spring softens the shock loads, and damages cause by

them on the vehicle body, joints and passengers on board.

Tomas W. Birch noticed that spring flattens as it absorbs the load and regains its original

curve once the load is removed. Flat and bent leafs have different lengths of fully leave. To

compensate this change in length shackle is introduced in the assembly of the leaf spring

system. Leaf spring also has sliding motion over each other which is called interleaf friction.

2. COMPOSITE MATERIALS:

Composite material is a material made up of two or more constituents combined together by

mechanical or chemical bonds. In composite materials constituents tend to retain their original

physical properties. Generally components of the composite material can be identified as

separate entities physically, and interface between them can be also be seen.

Page 3: DESIGN & ANALYSIS OF SANDWICH COMPOSITE …...Cite this Article: Shantanu Pawar, Dr. P. V. Jadhav and Dr. S. S. Chavan, Design & Analysis of Sandwich Composite Leaf Spring for Hmv,

Design & Analysis of Sandwich Composite Leaf Spring for Hmv

http://www.iaeme.com/IJMET/index.asp 3 [email protected]

Many composite materials are known to have superior structural performance when

compared with the conventional materials. They are generally superior when it comes to

strength to weight ratio and so are sought as a replacement of the steel in many applications.

Many physical properties can be tailored by adding components with different qualities to

make superior composite material Composites can be used to manufacture leaf springs, drive

shafts, road wheels and many other chassis components.

The metal matrix composite generally contain continuous or discontinuous fibers as

reinforcements of the size 0.1-0.5 µm in diameter and have a length to diameter ratio up to

200.Glass fiber reinforced polymer (GFRP) and carbon fiber reinforced polymer (CFRP) are

the examples of the polymer-ceramic composites which are generally used in the

manufacturing of the leaf springs for F1 racing cars. Bodies of the aircrafts, kayaks and boats

are made up of GFRP. Different manufacturing processes like hand layup, spray layup three

dimensional printing, compression molding can be used to manufacture the composite

materials.

3. LITERATURE REVIEW

Topic - Design and Analysis of Leaf Spring by Using Composite Material for Light

Vehicles

Author - Syambabu Nutalapati

Material - GFRP (Glass fiber reinforced polymer) & Epoxy

Weight Reduction – 85%

Remark - Better strength to weight ration and corrosion resistance

Topic - Analysis on GFRP Leaf Spring

Author - Akhil Mehndiratta et.al.

Material - GFRP (Glass fiber reinforced polymer) & Epoxy

Weight Reduction – 86.42%

Remark - Same deflection under same load, Similar bending stress

Topic - Experimental Analysis of Epoxy- Glass Fiber composite Leaf Spring for Natural

Frequency of Leaf Spring to Reduce the Vibration

Author - Jeevan Herekar et. al.

Material - GFRP (Glass fiber reinforced polymer) & Epoxy

Weight Reduction – 67%

Remark - Stress level is same in both the springs of steel & glass leaf; as cross section

area is same. Reduction in mass of glass fiber leaf, suspension performance will be greater

than leaf spring

Topic - Design and Material Optimization of Heavy Vehicle Leaf Spring

Author - T. N. V. Ashok Kumar et. al

Material - GFRP (Glass fiber reinforced polymer), Kevlar & Epoxy

Weight Reduction – 27.5%

Remark – Results for the frequency, deformation and stress are good than steel leaf

spring

Topic - Analysis of Steel and Composite Leaf Spring for Vehicle

Author - Ghodake A. P et. al.

Material - GFRP (Glass fiber reinforced polymer) & Epoxy

Weight Reduction – 85%

Page 4: DESIGN & ANALYSIS OF SANDWICH COMPOSITE …...Cite this Article: Shantanu Pawar, Dr. P. V. Jadhav and Dr. S. S. Chavan, Design & Analysis of Sandwich Composite Leaf Spring for Hmv,

Shantanu Pawar, Dr. P. V. Jadhav and Dr. S. S. Chavan

http://www.iaeme.com/IJMET/index.asp 4 [email protected]

Remark – GFRP can be utilized to create the leaf spring for light vehicles and can be a

successful trade for steel. GFRP has high quality to weight proportion, strain vitality

stockpiling limit when contrasted and steel

Topic - Analytical and Experimental Studies on Fatigue Life Prediction of Steel and

Composite Multi-leaf Spring for Light Passenger Vehicles Using Life Data Analysis

Author - Mouleeswaran Senthil Kumar et. al.

Material - GFRP (Glass fiber reinforced polymer) & Epoxy

Remark – Composite leaf spring is found to have 70 % less anxiety, 65% higher

solidness, 127% higher characteristic frequencies than steel spring.

Topic - Mono Composite Leaf Spring for Light Weight Vehicle – Design, End Joint

Analysis and Testing

Author - Gulur Siddaramanna, SambagamVijayarangan

Material - GFRP (Glass fiber reinforced polymer) & Epoxy

Weight Reduction – 85%

Remark – Give ease manufacture to mono composite leaf spring and composite leaf

spring with reinforced closures.

Topic - Modelling and Analysis of Composite as an Alternative Material for Leaf Spring

Author - Smita C. Sadhu, Vikas V. Shinde

Material - GFRP (Glass fiber reinforced polymer) & Epoxy

Remark – Reduce the weight while retaining strength similar for product

Topic - Reduce the weight while retaining strength similar for product

Author - Ashish V. Amrute et. al.

Material - GFRP (Glass fiber reinforced polymer) & Epoxy

Remark – Result out weight saved by the replacement of steel with GFRP in this

particular design. CAE analysis is performed on the both the designs. Results are compared

with the theoretical outputs.

Topic - Analysis and optimization of a composite leaf spring

Author - Mahmood M. Shokrieh

Material - GFRP (Glass fiber reinforced polymer) & Epoxy

Weight Reduction – 80%

Remark – Stresses are seen to be low in the enhanced outline for similar stacking

conditions and high normal frequencies are watched. Examination comes about are

additionally contrasted and the genuine made streamlined model.

Topic - Design of single composite leaf spring for light weight vehicle

Author - Achamyeleh a kassie

Material - GFRP (Glass fiber reinforced polymer) & Epoxy

Weight Reduction – 20%

Remark – Stresses are observed to be well within the acceptance criteria of static as well

as fatigue stress limit for the GFRP material

Topic - Modelling and Analysis of Suspension System of TATA SUMO by using

Composite Material under the Static Load Condition by using FEA

Author - Mr.Nisar S. Shaikh et. al.

Material - CFRP (Carbon fiber reinforced polymer) & Epoxy

Page 5: DESIGN & ANALYSIS OF SANDWICH COMPOSITE …...Cite this Article: Shantanu Pawar, Dr. P. V. Jadhav and Dr. S. S. Chavan, Design & Analysis of Sandwich Composite Leaf Spring for Hmv,

Design & Analysis of Sandwich Composite Leaf Spring for Hmv

http://www.iaeme.com/IJMET/index.asp 5 [email protected]

Remark – Design loading conditions carbon fibre leaf spring design is softer than the

steel and is prone to have better ride comforts on the plain roads. But in bad road conditions

stone hitting from below may damage the epoxy layer on the CFRP spring which might result

in loosing resilience. Also ANSYS FEA results are in conformance with the practical testing

results of the CFRP spring at the lower loading conditions when loading goes towards the

higher end the results do not match.

Topic - The modelling, stress analysis and material optimization of master leaf spring and

comparison of deformation and stress results between steel leaf spring and composite leaf

springs under same conditions

Author - N. AnuRadha, C. Sailaja et. al.

Material - CFRP (Carbon fiber reinforced polymer) & Epoxy

Remark – Creators concentrated on the displaying, static basic examination and

streamlining of leaf spring and contrasting anxiety and disfigurement after effects of steel and

composite leaf springs at comparative stacking conditions. After the playing out the

hypothetical and viable investigation they infer that composite leaf spring can supplant

ordinary spring.

Topic - Analysis of Composite Leaf Spring Using FEA for Light Vehicle Mini Truck

Author - Sorathiya Mehul et. al.

Material - CFRP (Carbon fiber reinforced polymer) & Epoxy

Weight Reduction – 70.6%

Remark – Results for FEA examination on steel leaf spring and composite Multi leaf

spring, Sought to look at solidness, weight, stack conveying limit and weight spare. While

outlining full knock stacking in kg is considered.

Topic - Static Analysis and Fatigue Life prediction of Composite Leaf Spring for a Light

Commercial Vehicle (TATA ACE)

Author - Manjunath H. N et. al.

Material - Graphite/Epoxy and Boron/Aluminium & Epoxy

Remark – Great execution in weakness when contrasted with ordinary steel spring with

comparative plan particulars. FEA comes about are coordinating with the hypothetical

esteems. Boron/Aluminium has minimum anxiety and distortion, and shows' high firmness

when contrasted and different composites.

Topic - Numerical And Experimental Stress Analysis Of A Composite Leaf Spring

Author - Kaveri A. Katake, Sham H. Mankar, Sandip A. Kale

Material - GFRP (Glass fiber reinforced polymer), (Carbon fiber reinforced polymer) &

Epoxy

Remark - With the assistance of investigation , hypothetical and pragmatic testing of the

leaf spring made and made by fluctuating every one of these parameters are considered and

comes about are looked at. Examination demonstrates that composite materials can be viably

utilized for substitution of steel leaf spring in the utilization of LMV.

4. DESIGN DETAILS

The design parameter for TATA ACE using rear three leaf spring with his material properties

are given in table

Page 6: DESIGN & ANALYSIS OF SANDWICH COMPOSITE …...Cite this Article: Shantanu Pawar, Dr. P. V. Jadhav and Dr. S. S. Chavan, Design & Analysis of Sandwich Composite Leaf Spring for Hmv,

Shantanu Pawar, Dr. P. V. Jadhav and Dr. S. S. Chavan

http://www.iaeme.com/IJMET/index.asp 6 [email protected]

Table 1 Design Parameter and Material Properties of Steel Leaf Spring

Parameter Value

Material selected– Steel 65si7

Length of leaf spring eye to eye 890 mm

Camber height 63 mm

Width of the leaf 63 mm

Thickness of each leaf 8 mm

No. of full length leaf 2

No. of Graduated leaf 1

Yield strength 1470 N/mm2

Tensile strength 1962 N/mm2

Young’s modulus (E) 2.1x105 N/mm

2

Design stress (σb) 653 N/mm2

Spring rate 65 N/mm

Maximum load carrying capacity 6250 N

Spring weight 15 kg

Table 2 Design Parameter and Material Properties of Composite Leaf Spring

Parameter Value

Tensile modulus of Carbon Fiber along X-axis 270000 N/mm2

Tensile modulus of E-glass Fiber along X-axis 76000 N/mm2

Tensile modulus of matrix along X-axis 2800 N/mm2

Weight Ratio 0.607/0.393

Young’s modulus (Ex) 31547.79 N/mm2

Tensile strength 405.33 N/mm2

Length of leaf spring Eye to Eye 890 mm

Arc height at axle seat (Camber) 63 mm

Width 50 mm

Thickness 22 mm

5. FINITE ELEMENT ANALYSIS

The finite element analysis (FEA) for steel leaf spring is carried by ANSYS 15.0 Workbench

software. The steel leaf spring is design in CATIA V5 part modeling and assembly. Master

leaf, full length leaf, graduate leaf, bolt and nut each part are create in part modeling. In

assembly section assemble all part in sequences. After assemble model are save iges file.

Figure 2 Assemble Steel leaf spring

Page 7: DESIGN & ANALYSIS OF SANDWICH COMPOSITE …...Cite this Article: Shantanu Pawar, Dr. P. V. Jadhav and Dr. S. S. Chavan, Design & Analysis of Sandwich Composite Leaf Spring for Hmv,

Design & Analysis of Sandwich Composite Leaf Spring for Hmv

http://www.iaeme.com/IJMET/index.asp 7 [email protected]

This file is import in ANSYS Workbench geometry. Open the ANSYS Workbench

application in computer. First window open, selects static structural from toolbox, the static

structural analysis is integrated various step.

Step 1 Engineering Data:- Select the material properties for Steel 65si7 material are use in

steel leaf spring. And go back to project.

Figure 3 ANSYS Workbench Window

Step 2 Geometry:- When click the geometry section create a new window, in this new

window we create or import the model. Import the model is iges file, after that generate the

model.

Step 3 Model section also create a new window, in this window model are automatic

update. Now first point is Geometry, which is already generated. Second point is coordinate

system define. Third point is connection, all leaf together no separation and contact and target

area are defined. Fourth point is mesh; need to define the element size for stander model.

Consider the no. of node and element are generating in model.

Step 4 Setup in hare we define the boundary condition and apply the force/Pressure. The

steel leaf spring have two eye are connected the chassis and canter of the leaf spring is axial

which attach to wheel. So we consider one eye is remote displacement X,Y,Z direction is

constant, UY,UZ also constant and UX is free. Similar another eye X,Z,UY,UZ are constant

and Y,UX are free. The gradually point load is applied at canter of the leaf spring.

Figure 4 Boundary conduction on eye Figure 5 Apply load at the center of leaf spring

Step 5 Solution, is the final stage of pre-possessor it solve the problem.

Step 6 Result are show in window, in leaf spring we found the maximum stress and

displacement which is shown.

Page 8: DESIGN & ANALYSIS OF SANDWICH COMPOSITE …...Cite this Article: Shantanu Pawar, Dr. P. V. Jadhav and Dr. S. S. Chavan, Design & Analysis of Sandwich Composite Leaf Spring for Hmv,

Shantanu Pawar, Dr. P. V. Jadhav and Dr. S. S. Chavan

http://www.iaeme.com/IJMET/index.asp 8 [email protected]

Figure 6 The deflections for applying 6250 N force Figure 7 The von-Mises stress for applying

6250 N force

Table 3 FEA for steel leaf spring in various loads

FEA of steel leaf spring

Load

(N)

����

(mm)

����

(N/mm2)

Stiffness

(N/mm)

1000 9.51 109.79 105.13

2000 19.02 219.58 105.13

3000 28.54 329.37 105.13

4000 38.05 439.17 105.13

5000 47.56 548.75 105.13

6250 59.45 678.09 105.13

Figure 8 Load Vs Stress for FEA steel Figure 9 Load Vs displacement for FEA steel

Figure 8 and 9 shows graph for Load VS Stress and Load VS Displacement for Steel

respectively. As we increase the load, Stresses and displacement also increases proportionally

to load. Here we apply load 6250 N, and we find results for stress are 678.09 N/mm2

and for

displacement are 59.45 mm.

The mono composite leaf spring is laminate number of layers. Each layer is called fiber

and every layer is stick between resin each have individual mechanical properties. Both are

combining and make composite material properties, this mechanical property need to FEA

analysis. We use UD E-glass fiber and Epoxy 88 layers have each layer 0.25 mm (Young

Modulus 31547MPa). We use ANSYS 15 Workbench for FEA of mono composite analysis.

In this ANSYS go to static analysis, the new block is open in hear various section we discus

one by one. First is engineering data, in here we select the material for analysis. In ANSYS

Page 9: DESIGN & ANALYSIS OF SANDWICH COMPOSITE …...Cite this Article: Shantanu Pawar, Dr. P. V. Jadhav and Dr. S. S. Chavan, Design & Analysis of Sandwich Composite Leaf Spring for Hmv,

Design & Analysis of Sandwich Composite Leaf Spring for Hmv

http://www.iaeme.com/IJMET/index.asp 9 [email protected]

have provide all type engineering material data sheet, so we select the wet UD E-

Glass/Epoxy, this mechanical properties is match our material properties.

Figure 10 Engineering data source provide E-Glass/Epoxy material properties

Go back to static analysis window. After that go to geometry section, in here import the

geometry file which have all reedy create and save in iges format and generate.

Figure 11 Geometry of Mono composite leaf spring

After that go to model, in model section have various step geometry is first in here select

the material fir body. The meshing section is define element size 5 mm and mesh, after that

boundary condition is apply, one eye have only z-rotation free and all other have fixed and

another eye side z-rotation and x-direction have free other is fixed. After load is apply in

center 6250 N load and get result of total deformation and maximum stress.

Figure 12 Meshing of the model

Page 10: DESIGN & ANALYSIS OF SANDWICH COMPOSITE …...Cite this Article: Shantanu Pawar, Dr. P. V. Jadhav and Dr. S. S. Chavan, Design & Analysis of Sandwich Composite Leaf Spring for Hmv,

Shantanu Pawar, Dr. P. V. Jadhav and Dr. S. S. Chavan

http://www.iaeme.com/IJMET/index.asp 10 [email protected]

Figure 13 Boundary Condition on eye

Figure14 Loading condition

Figure 15 Total deformation on 6250 N load

Figure 16 Maximum stress on 6250 N load

Page 11: DESIGN & ANALYSIS OF SANDWICH COMPOSITE …...Cite this Article: Shantanu Pawar, Dr. P. V. Jadhav and Dr. S. S. Chavan, Design & Analysis of Sandwich Composite Leaf Spring for Hmv,

Design & Analysis of Sandwich Composite Leaf Spring for Hmv

http://www.iaeme.com/IJMET/index.asp 11 [email protected]

FEA static analysis of mono composite leaf spring is analyzed and we also analysis

include carbon 4 layer top and bottom and in between E-Glass 80 layer, total thickness is 22

mm each layer have 0.25 mm thickness. We select carbon for this analysis because carbon

fiber have higher mechanical properties (double of glass), and we observe in before analysis

top and bottom surface generate higher stress so apply this carbon fiber material 4 layer have

1 mm thinness top and bottom side model have 20 mm E-Glass. Now go to analysis and

observe that. Again go to static analysis, we select the material from engineering data source

select the UD E-Glass/Epoxy and Woven Carbon/Epoxy.

Table 4 Material properties of GFRP and CFRP

Import the leaf spring geometry in .iges format in geometry section.

Figure 17 Carbon layer shown on top in laminate

Now in model section define Carbon/Epoxy material for top and bottom layer and center

layer have E-Glass/Epoxy. Fine mesh is meshing, same boundary condition and force is

apply, where define in previous.

Figure 18 Total deformation on 6250 N load

Figure 18 shows Total Deformation on 6250 N is 51.295 mm for mono composite leaf

spring

Page 12: DESIGN & ANALYSIS OF SANDWICH COMPOSITE …...Cite this Article: Shantanu Pawar, Dr. P. V. Jadhav and Dr. S. S. Chavan, Design & Analysis of Sandwich Composite Leaf Spring for Hmv,

Shantanu Pawar, Dr. P. V. Jadhav and Dr. S. S. Chavan

http://www.iaeme.com/IJMET/index.asp 12 [email protected]

Figure 19 Maximum stress generate on 6250 N load

In Figure 19 maximum stress generates on 6250 N load is 510.43 N/mm2.

Figure 20 Stress generate on top carbon layer only

Now we apply condition stress generate on top carbon layer only in figure 20 and we got

results are 509.48 N/mm2

Figure 21 Stress generate on E-glass layer only

Stress generate on E-glass layers only in mono composite leaf spring are 265.01 N/mm2

shown in figure 21.

Figure 22 Stress generate on Bottom carbon layer only

Page 13: DESIGN & ANALYSIS OF SANDWICH COMPOSITE …...Cite this Article: Shantanu Pawar, Dr. P. V. Jadhav and Dr. S. S. Chavan, Design & Analysis of Sandwich Composite Leaf Spring for Hmv,

Design & Analysis of Sandwich Composite Leaf Spring for Hmv

http://www.iaeme.com/IJMET/index.asp 13 [email protected]

In figure 22, we got results for stress generate on bottom carbon layer only are 510.43

N/mm2 and FEA for mono composite leaf spring in various loads are shown in table 5.

Table 5 FEA for mono composite leaf spring in various loads

Graphical representation of load Vs displacement and load Vs stress

Figure 23 Load Vs displacement for FEA composite leaf spring

Composite effect of only glass and carbon layer at top and bottom is shown in above

figure number 5.23. The leaf spring with carbon has reported less displacement then the only

glass fiber epoxy.

Figure 24 Load Vs stress for FEA composite leaf spring

Analysis of the stress for the middle and center layers of Mono composite leaf spring is

done, where center layer is glass fiber lamina have less stress, due to less load applied at the

center are compare to the load at top and bottom layers. So maximum stress is on top layers

(carbon) in leaf spring

0

20

40

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80

10

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Carbon/Epox

y Composite

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Glass/Epoxy

Stress

Page 14: DESIGN & ANALYSIS OF SANDWICH COMPOSITE …...Cite this Article: Shantanu Pawar, Dr. P. V. Jadhav and Dr. S. S. Chavan, Design & Analysis of Sandwich Composite Leaf Spring for Hmv,

Shantanu Pawar, Dr. P. V. Jadhav and Dr. S. S. Chavan

http://www.iaeme.com/IJMET/index.asp 14 [email protected]

6. TESTING OF MONO COMPOSITE LEAF SPRING IN UTM

Testing of leaf spring is carried out on Unidirectional testing machine (UTM) in Praj Lab.

Kothrud, pune. Composite leaf spring attached in C-channel. In this testing composite leaf

spring are free from two sides, means any side is not fixed. Now applying gradually load of

50mm/min speed under testing software.

Table 6 Testing result

Load vs. Deflection

Load Deflection Stiffness

1000 14.8 67.56

2000 28.6 69.93

3000 41.6 72.11

4000 53.2 75.19

5000 63.0 79.36

6250 71.3 87.65

Figure 25 Testing Process

7. RESULTS

STATICAL ANALYSIS, FEA AND TESTING RESULTS

In factual computations of steel leaf spring and mono composite leaf spring, we found that

steel leaf spring has greatest burden conveying limit of 6250 N. At the point when most

extreme burden is connected than the anxiety is reasonable however diversion is close to

camber stature and if apply 7000 N stack then it goes to camber tallness. Be that as it may, in

mono composite leaf spring condition is similar; the analytical of mono composite leaf spring

is approximately. In FEA of steel leaf spring and mono composite leaf spring result is similar

to analytical analysis.

But testing result is more deflection; in 5000 N load have similar camber height deflection

and increasing load the deflection is cross the camber height. In here we need to improve the

load carrying capacity by using Carbon fiber in outer layer. This mono composite leaf spring

is easily carrying the vehicle load but when get maximum load then may be create problem. In

normal condition well perform. The stress of steel leaf spring have slightly more than design

stress, it is not a bigger problem because ultimate stress of steel is more, so safe design

consider and FEA solution result is the approximately similar. In mono composite have much

Page 15: DESIGN & ANALYSIS OF SANDWICH COMPOSITE …...Cite this Article: Shantanu Pawar, Dr. P. V. Jadhav and Dr. S. S. Chavan, Design & Analysis of Sandwich Composite Leaf Spring for Hmv,

Design & Analysis of Sandwich Composite Leaf Spring for Hmv

http://www.iaeme.com/IJMET/index.asp 15 [email protected]

less stress compare to steel but the composite material maximum stress is 405 MPa and in

calculation we got 325 MPa is generate on 6250 N load. So design is safe and stress

permissible.

Graphical Representation of Displacement and Stress

Figure 26 comparative Graph between Load Vs displacement

The statistical calculation, Finite analysis of steel and composite leaf spring has shown

linear curve where displacement is increased as the load increases gradually. The statistical

and FEA calculations are matching for steel and composite material.

Figure 27 comparative Graph between Load Vs stress

From above figure we concluded that in the composite leaf spring at analytical calculation

and in FEA analysis minimum stress and strain generated as compared to steel leaf spring.

8. CONCLUSION

We have found that, when load 6250 N was applied on Steel leaf spring the analytical

calculation shows Deflection – 60.98 mm, Maximum Stress – 689.79 N/mm2 and Stiffness –

102.48 mm. The FEA result shows Deflection – 50.45 mm, Maximum Stress – 678.09 N/mm2

and Stiffness – 105.13 mm.

0

10

20

30

40

50

60

70

80

100020003000400050006250

dis

pla

cem

en

tLoad vs displacement

Statistical

calculations of

steel leaf spring

FEA of steel leaf

spring

0

100

200

300

400

500

600

700

800

Str

ess

Load vs Stress

Statistical

calculations of

steel leaf spring

FEA of steel leaf

spring

Page 16: DESIGN & ANALYSIS OF SANDWICH COMPOSITE …...Cite this Article: Shantanu Pawar, Dr. P. V. Jadhav and Dr. S. S. Chavan, Design & Analysis of Sandwich Composite Leaf Spring for Hmv,

Shantanu Pawar, Dr. P. V. Jadhav and Dr. S. S. Chavan

http://www.iaeme.com/IJMET/index.asp 16 [email protected]

On same load for Mono Composite Leaf Spring, we find

The analytical calculation shows Deflection – 65.58 mm, Maximum Stress – 344.78 N/mm2

and Stiffness – 95.03 mm. The FEA result shows Deflection – 60.04 mm, Maximum Stress –

325.15 N/mm2 and Stiffness – 104.09 mm. The testing result shows Deflection – 71.03 mm

and Stiffness – 87.65 mm for testing results. By results, we conclude that the Carbon-Glass-

Carbon Epoxy Mono Composite Leaf spring shows 91.55 % efficiency analytically to FEA

results and 83.04 % efficiency testing results to FEA results. That means it might be

allowable for replacement for Steel leaf spring because efficiency is below 20 %.

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