design & analysis of sandwich composite …...cite this article: shantanu pawar, dr. p. v....
TRANSCRIPT
![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,](https://reader034.vdocuments.mx/reader034/viewer/2022050519/5fa32662438f3d556252be9a/html5/thumbnails/1.jpg)
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,](https://reader034.vdocuments.mx/reader034/viewer/2022050519/5fa32662438f3d556252be9a/html5/thumbnails/2.jpg)
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,](https://reader034.vdocuments.mx/reader034/viewer/2022050519/5fa32662438f3d556252be9a/html5/thumbnails/3.jpg)
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,](https://reader034.vdocuments.mx/reader034/viewer/2022050519/5fa32662438f3d556252be9a/html5/thumbnails/4.jpg)
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,](https://reader034.vdocuments.mx/reader034/viewer/2022050519/5fa32662438f3d556252be9a/html5/thumbnails/5.jpg)
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,](https://reader034.vdocuments.mx/reader034/viewer/2022050519/5fa32662438f3d556252be9a/html5/thumbnails/6.jpg)
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,](https://reader034.vdocuments.mx/reader034/viewer/2022050519/5fa32662438f3d556252be9a/html5/thumbnails/7.jpg)
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,](https://reader034.vdocuments.mx/reader034/viewer/2022050519/5fa32662438f3d556252be9a/html5/thumbnails/8.jpg)
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,](https://reader034.vdocuments.mx/reader034/viewer/2022050519/5fa32662438f3d556252be9a/html5/thumbnails/9.jpg)
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,](https://reader034.vdocuments.mx/reader034/viewer/2022050519/5fa32662438f3d556252be9a/html5/thumbnails/10.jpg)
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,](https://reader034.vdocuments.mx/reader034/viewer/2022050519/5fa32662438f3d556252be9a/html5/thumbnails/11.jpg)
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,](https://reader034.vdocuments.mx/reader034/viewer/2022050519/5fa32662438f3d556252be9a/html5/thumbnails/12.jpg)
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,](https://reader034.vdocuments.mx/reader034/viewer/2022050519/5fa32662438f3d556252be9a/html5/thumbnails/13.jpg)
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
60
80
10
00
20
00
30
00
40
00
50
00
62
50
Dis
pla
cem
en
t
Load Vs Displacement
E-
Glass/Epoxy
Composite
Carbon E-
Glass
Carbon/Epox
y Composite
0
100
200
300
400
500
600
10
00
20
00
30
00
40
00
50
00
62
50
Str
ess
Load Vs Stress
E-Glass/Epoxy
Stress
Center E-
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,](https://reader034.vdocuments.mx/reader034/viewer/2022050519/5fa32662438f3d556252be9a/html5/thumbnails/14.jpg)
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,](https://reader034.vdocuments.mx/reader034/viewer/2022050519/5fa32662438f3d556252be9a/html5/thumbnails/15.jpg)
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,](https://reader034.vdocuments.mx/reader034/viewer/2022050519/5fa32662438f3d556252be9a/html5/thumbnails/16.jpg)
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 %.
REFERENCES
[1] Syambabu Nutalapati, Design and Analysis of Leaf Spring by Using Composite Material
for Light Vehicles, International Journal of Mechanical Engineering and Technology
(IJMET), Volume 6, Issue 12, Dec 2015, pp. 36-59.
[2] Mehndiratta, Nand Kishore Singh, Kalyan Kumar Singh, Analysis of GFRP Leaf Spring,
International Journal of Modern Engineering Research (IJMER), Vol. 5, Iss. 5, May 2015,
Pp-22-27.
[3] Jeevan Herekar, Prof. Kishor Ghatage, Prof. Narayanrao Hargude, Experimental Analysis
of Epoxy- Glass Fiber composite Leaf Spring for Natural Frequency of Leaf Spring to
Reduce the Vibration International Journal Of Innovations In Engineering And
Technology , Volume 5 Issue 2 - April 2015, Pp-187-198.
[4] T. N. V. Ashok Kumar, E. Venkateswara Rao, Design and Material Optimization of
Heavy Vehicle Leaf Spring International Journal of research In Mechanical engineering
& technology, Vol. 4, Issue spl - 1, No V 2013 - April 2014.
[5] Ghodake A. P., Patil K. N. Analysis Of Steel And Composite Leaf Spring For Vehicle,
IOSR, Journal Of Mechanical And Civil Engineering (Iosr-Jmce), 2278-1684 Volume 5,
Issue 4 (Jan. - Feb. 2013), Pp 68-76.
[6] Mouleeswaran Senthil Kumar, Sabapathy Vijayarangan presented Analytical and
Experimental Studies on Fatigue Life Prediction of Steel and Composite Multi-leaf Spring
for Light Passenger Vehicles Using Life Data Analysis” Research Gate Materials Science,
Vol. 13, No. 2. 2007, Pp-141-146.
[7] Gulur Siddaramanna, Sambagam Vijayarangan, Mono Composite Leaf Spring for Light
Weight Vehicle – Design, End Joint Analysis and Testing. ISSN 1392–1320 Material
Science (Medžiagotyra). Vol. 12, No. 3. 2006.
[8] Smita C. Sadhu, Vikas V. Shinde Modelling and Analysis of Composite as an Alternative
Material for Leaf Spring. IOSR Journal of Mechanical and Civil Engineering (IOSR-
JMCE), ISSN: 2278-1684, p-ISSN: 2320-334X, Vol 11, Issu 3 Ver. IV (May- Jun. 2014).
[9] Ashish V. Amrute, Edward Nikhil karlus, Design and assessment of multi leaf spring,
IJRAME, Vol.1 Issue.7, November 2013. Pgs: 115-124.
[10] Mahmood M. Shokrieh, Analysis and optimization of a composite leaf spring. Elsevier
Composite Structures, doi:10.1016/S0263-8223(02) 00349-5
[11] Achamyeleh a Kassie, Design of single composite leaf spring for light weight vehicle,
IJMERR, ISSN 2278 – 0149, Vol. 3, No. 1, January 2014.
[12] Mr. Nisar S. Shaikh, Prof. S. M. Rajmane, Modelling and Analysis of Suspension System
of TATA SUMO by using Composite Material under the Static Load Condition by using
FEA. International Journal of Engineering Trends and Technology (IJETT), Volume 12
Number 2, Jun 2014, Pp-64-73.
[13] N. AnuRadha, C. Sailaja, S. Prasad Kumar, U. Chandra Shekar Reddy & Dr. A. Siva
Kumar, Stress Analysis and Material Optimization of Master Leaf Spring, International
Journal Of Application Or Innovation In Engineering & Management, Volume 2, Issue
10, October 2013, Pp-324-329.
![Page 17: 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,](https://reader034.vdocuments.mx/reader034/viewer/2022050519/5fa32662438f3d556252be9a/html5/thumbnails/17.jpg)
Design & Analysis of Sandwich Composite Leaf Spring for Hmv
http://www.iaeme.com/IJMET/index.asp 17 [email protected]
[14] Sorathiya Mehul, Dhaval B. Shah, Vipul Bhojawala, Analysis Of Composite Leaf Spring
Using FEA For Light Vehicle Mini Truck, Journal Of Information, Knowledge and
Research In Mechanical Engineering, Nov 12 To Oct 13, Volume 2, Issue 2, Pp. 424-428.
[15] Manjunath H. N, Manjunath. K, T. Rangaswamy, Static Analysis and Fatigue Life
Prediction Of Composite Leaf Spring For A Light Commercial Vehicle (Tata Ace),
International Journal Of Engineering Research, Volume No.3, Issue No.7, Pp. 422-425.
[16] Kaveri A. Katake, Sham H. Mankar, Sandip A. Kale, Numerical and experimental stress
analysis of a composite leaf spring, International Journal of Engineering and Technology
(IJET). ISSN (Print: 2319-8613 ISSN (Online): 0975-402.
[17] T. H. Sanders - Laminated springs
[18] https://en.wikipedia.org/wiki/Kevlar
[19] D V Ramanareddy, B.Subbaratnam, E. Manoj Kumar and Perala Kalyan Praneeth, Design
and Analysis of Composite Leaf Spring, International Journal of Mechanical Engineering
and Technology, 8(6), 2017, pp. 494–500
[20] N.Vijaya Rami Reddy, K.Sudhakar Reddy, A.Chinna Mahammad Basha, B. Rajnaveen,
Design and Analysis of Composite Leaf Spring for Military Jeep. International Journal of
Mechanical Engineering and Technology, 8(4), 2017, pp. 47–58.
[21] Chintada. Vinod Babu, M. Vykunta Rao and U. Sudhakar, Analysis of Composite Leaf
Spring: A Comparison, International Journal of Mechanical Engineering and Technology,
8(6), 2017, pp. 688-694