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Structural Analysis of Leaf Spring

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Aim: To determine maximum bending stress in Leaf Spring

Problem Definition: Determining the magnitude of stress

induced in order to improve the design of Leaf Spring. Multi leaf
springs used in automotive vehicles normally consists of full length
leaves and graduated length leaves. The specimen under this research
work consists of nine leaves, two eye pins, centre bolt with nut etc.
CAE tools are being used to analyze the robustness and performance
of components and assemblies.

Analysis:

Design parameters of the multi leaf spring used in this work are:
Number of full length leaves: 02
Length of full length leaves (L-1 and L-2): 1450 mm each

Parameters Value:

1) Calculations :
Assumptions:
1)
2)
3)
4)
5)
6)
7)
8)
9)

Total span length (eye to eye) 2L: 1450mm

Width of all leaves b: 70mm
Thickness of all leaves t: 70mm
Total number of leaves n
Material of Spring Structural Steel
Youngs Modulus, E 2.1105 MPa
Poissons Ratio, 0.3
Tensile Strength Ultimate 450 MPa Tensile
Density 7.8610-6 Kg/mm

Step 1: Finding Convective heat transfer coefficient (h) :

1) Re = (a*v0*D)/ a
= (1.225*27.77*0.240) / 0.00018
= 45.35 * 103
2) Pr=( cp*a) / ka
= ( 1004.5*0.00018) / 0.262
= 0.7
3) Nu = ( 0.3387 * Re1/2 * Pr1/3 ) / {1 + (0.0468/Pr)2/3 }1/4
= [ 0.3387 * {45.35*103}1/2 * 0.71/3] / [ 1 + (0.0468/0.7)2/3]1/4
= 62.152
4) Nu = h * D / ka
62.152 =h * 0.240 / 0.262
h = 55.30 W/m2K
Step 2: Finding Heat Flux (Q):
5) Kinetic Energy (KE) =[m * v02 * k * r ] / 2
= [ 350*27.772*0.9*0.3]/2
= 18.218*10^3 J
Where- k= Percent Energy Transfer=90%

r = Axle weight distribution = 30%

6) Finding stopping Time :
V2 = V02 2*a*s
1 = 27.772 2*a*25
a = 16.67 m/s2
As this is deceleration- a = -16.67 m/s2
v = v0 + at
0= 27.77 16.67 * t
t = 2 sec

Meshing of the Leaf Spring Assembly

2) Finite Element Analysis Method:

Application of Loading & Boundary Conditions

Results :

Equivalent von-Mises Stress

Validation :

Calculation for maximum temperature rise:

Tmax = (0.527 * Q * t1/2) / [ * c * km]1/2 + Tamb
= ( 0.527*3907.54*21/2) / [ 7200*510*45] + 30
= 30.220 C
Where- = Density of rotor material
c = Specific heat of material
km= Thermal conductivity of material
The above temperature calculated is for one face of the brake rotor. Thus the
actual maximum temperature rise will beTmax = 60.44 0 C

Conclusion:
Validation calculation shows that the maximum
bending stress induced in the Leaf Spring is within
limits. Hence the design of leaf spring in terms of
bending stresses is validated.