Leaf Spring Documentation Ven

DESIGN AND ANALYSIS OF A LEAF SPRING
FOR LIGHT VEHICLE MINI TRUCKS
iii
ABSTRACT
In the present scenario weight reduction is the main focus of an automobile

manufacturer. Generally, leaf spring is used for suspension purposes in light &
heavy trucks. These springs are mainly made up of steel material which having
more weight. In order to reduce the weight, here composite leaf spring is used
instead of steel leaf spring. Composite materials are widely used in aeronautical,
marine and automotive industries, because of their excellent mechanical
properties, low density and ease of manufacture. Due to this increasing trend to
utilize composite materials, it has become necessary to investigate the pros and
cons of composites. Leaf springs are one of the oldest suspension components
that are being still used widely in automobiles. They contribute to 15-20%
unsprung weight. This work deals with the replacement of conventional steel leaf
spring with composite leaf spring. Comparison of steel and composite leaf spring
using ANSYS Software. The effects of change in design on the total deformation,
equivalent elastic strain and equivalent stress was studied by using ANSYS. The
leaf spring is modeled Using CATIA for the four-materials E glass epoxy, S glass
epoxy, Kevlar epoxy and carbon fibre.
iv
CONTENTS
Page No.
BONAFIDE CERTIFICATE i
CERRTIFICATE OF AUTHENTIFICATION ii
ACKNOWLEDGEMENT iii
ABSTRACT iv
CONTENTS v
LIST OF FIGURES viii
LIST OF TABLES x
CHAPTER 1: INTRODUCTION 1-19
BACKGROUND 1
INTRODUCTION OF SPRINGS 1-2
CLASSIFICATIONS OF SPRINGS 2-8
LEAF SPRING TERMONOLOGY 8-11
MATHEMATICAL THEORY OF LEAF SPRINGS 11-16
COMPUTER AIDED DESIGN 17-18
CHAPTER 2: LITERATURE REVIEW 20-23
CHAPTER 3: METHODOLOGY 23-30
INTRODUCION 23
COMPUTER AIDED DESIGNING 23-24
CAE SOFTWARE PACKAGES 24-30
3.3.1 CATIA 25-26
ANSYS WORKBENCH 27
v
CAE ANALYSIS 28
FEA PROCEDURE IN ANSYS 28-30
CHAPTER 4: MODELING IN CATIA V5 31
CHAPTER 5: STATIC ANALYSIS OF LEAF SPRING 32-38
ANSYS 32
NON LINEAR STATIC ANALYSIS 33-34
Nonlinear behavior 33-34
ANALYSIS FLOW CHART 34
Steps involved in procedure 34
DEFINE IN ANSYS 35
TASK TO BE DONE IN ANASYS 35
SOLUTION METHODS ADOPTED 35
ANALYSIS PROCEDURE 36-43
LAUNCHING ANSYS WORKBENCH 36
PRE PROCESSING (SETTING UP THE MODEL) 36-37
ENGINEERING DATA 37-38
IMPORTING THE MODEL OF LEAF SPRING 39
MESHING 40
APPLYING BOUNDARY CONDITIONS & LOAD 41
POST PROCESSING (SOLUTION) 43
CHAPTER 6: RESULTS AND DISCUSSION 45-52
STATIC ANALYSIS 45
RESULTS OF CARBON FIBER LEAF SPRING 45
v
RESULTS OF CONVENTIONAL LEAF SPRING 46
RESULTS OF E GLASS EPOXY LEAF SPRING 48
RESULTS OF S GLASS EPOXY LEAF SPRING 49
RESULTS OF KEVLAR EPOXY LEAF SPRING 50
COMPARISION OF RESULTS 52
CHAPTER 7: COCLUSION 53
CHAPTER 8: REFERENCES 54-55
v
LIST OF FIGURES
Figure 1.1: Tension & Compression Springs 3

Figure 1.2: Conical & Torsion Spring 3
Figure 1.3: Spiral & Leaf Springs 4
Figure 1.4: Flat leaf spring 5
Figure 1.5: Multi leaf spring 5
Figure 1.6: Multi-stage leaf spring 6
Figure 1.7: Parabolic leaf spring 6
Figure 1.8: Shapes of Eye Ends 7
Figure 1.9: Open Eye End 7
Figure 1.10: Slipper Eye End 8
Figure 1.11: Military Wrapper Eye End 8
Figure 1.12: Multi Leaf Spring Terminologies 9
Figure 1.13: Improper Stepping of Leaf Spring 10
Figure 1.14: Nipping of Leaf Spring 11
Figure 1.15: Leaf as Cantilever Beam 11
Figure 1.16: Leaf as Simply Supported Beam 13
Figure 1.17: Multi Cantilever Beam 13
Figure 1.18: Quarter Leaf Spring through Triangular Plate 14
Figure 1.19: Multi Leaf Spring through Rectangular Plate 15
Figure 1.20: CAD Composition 17
Figure 1.21: Light vehicle mini truck 19
Figure 3.1: CAD - CAM - CAE Relationship 24
Figure 3.2: Two-Dimensional Tool Bars of CATIA 25
Figure 3.3: Three-Dimensional Tool Bars of CATIA 26
Figure 3.4: FEA Flow Chart of ANSYS 30
Figure 4.1: Design of Leaf spring 31
Figure 5.1 Mesh generation 34
Figure 5.2 Stress vs Strain 35
Figure 5.3: Ansys workbench 16.2 window 36
Figure 5.4: Static structural panel 37
viii
Figure 5.5: Selection of engineering Data 39
Figure 5.6: Imported CATIA leaf spring model 40
Figure 5.7: Meshed leaf spring 41
Figure 5.8: Tool bar options for meshing 41
Figure 5.9: Applying boundary conditions 42
Figure 5.10: Applying force 43
Figure 5.11: solution total deformation 43
Figure 5.12: solving equivalent stress 44
Figure 5.13: Solving equivalent strain 44
Figure 6.1: Carbon fibre Deformation 45
Figure 6.2: Carbon fibre Equivalent stress 45
Figure 6.3: Carbon fibre Equivalent strain 46
Figure 6.4: Conventional steel Leaf spring Deformation 46
Figure 6.5: Conventional steel Leaf spring stress 47
Figure 6.6: Conventional steel Leaf spring strain 47
Figure 6.7: E Glass deformation 48
Figure 6.8: E Glass Equivalent Stress 48
Figure 6.9: E Glass Equivalent Strain 48
Figure 6.10: S Glass deformation 49
Figure 6.11: S Glass Equivalent stress 49
Figure 6.12: S Glass Equivalent Strain 50
Figure 6.13: Kevlar deformation 50
Figure 6.14: Kevlar Equivalent stress 51
Figure 6.15: Kevlar Equivalent strain 51
ix
LIST OF TABLES
Table -5.1: Material properties of steel leaf spring 38

Table -5.2: Material properties of carbon fiber 38
Table-5.3: Material properties of E glass epoxy 38
Table-5.4: Material properties of S glass epoxy 38
Table-5.5: Material properties of Kevlar epoxy 39
Table -6.1: Carbon fiber leaf spring results 46
Table -6.2: conventional steel leaf spring results 47
Table -6.3: E Glass epoxy leaf spring results 49
Table -6.4: S Glass epoxy leaf spring result 50
Table -6.5: Kevlar leaf spring result 51
Table -6.6: Result comparison of all leaf springs 52
x
1.INTRODUCTION
BACKGROUND
There is growing demand from the industries for the development of new concepts and
approach to meet the new challenges in the field of manufacturing engineering. Some research
and improvements are always necessary in the present level of technology to achieve the
demands of modern industrial world and customers. The fatigue failure of leaf springs,
strength and weight reduction are primary concern at present. This work has been done using
computer aided engineering analysis which is based upon a mathematical technique called
finite element method. The component chosen for this purpose is leaf springs which find
widespread application in the suspension systems of automotive vehicles. Though several
attempts were made to evaluate fatigue and fretting behaviour of leaf springs using stress
based and crack-based approach but the present work is on the CAE analysis of leaf springs
and then experimentally validation by stress-based approach. The analysis is accomplished by
adopting new technologies for production, modification in designs or replacing the existing
materials with the newer ones having better properties. Computer aided engineering analysis
of the leaf springs has been done and then validated through the results of experimental testing
in manufacturing industry. Before proceeding in detail, it is required to get introduce with the
suspension springs & specifically with the leaf springs in the next section.
INTRODUCTION OF SPRINGS
A spring is a resilient object used to soak up unwanted mechanical energy which is available
in the form of shocks & vibrations. Springs are usually made out of hardened steel
called spring steel. Small springs can be wound from pre-hardened stock, while larger ones are
made from annealed steel and hardened after fabrication. Some non-ferrous metals are also
used including phosphor and titanium for parts requiring corrosion resistance and beryllium
copper for springs carrying electrical current. Springs are disparate to other machine
components in that they undergo significant deformation when loaded and stores recoverable
mechanical energy. Springs were introduced in 13 thcentury in chariots which increases its
performance. Later spring was firstly used in pistols which made it possible to shot off by
single hand. Then again springs come into sight in early 1500 in door locks &evolved into
watches by the 1600. In 1763, R. Treadwell invented first ever coil spring and got it patent.
1
The first leaf spring was invented by Elliot of London in 1804. Henry Ford's 1908 Model-T
made a twist using leaf spring at axle transversely instead of using at each wheel. Therefore, it
has been found out that springs are fulfilling the need of a number of mechanical devices with
various aspects.
Following are the different applications of springs:
1. To provide cushioning effect by absorbing unwanted energy produced due to

shocks or vibrations in car, railway wagons, air-craft landing systems etc.
2. To exert force in brakes, clutches and various valves.
3. To control motion between two elements as in cam and followers.
4. To measure force in spring balances, engine indicators etc.
5. To store energy in different mechanical devices like watches & toys.
In the present work, suspension system of automotive vehicles is in focus, therefore, it is better
to discuss the function of spring in a vehicle suspension system i.e. when a wheel meets an
obstacle on the road surface; the spring allows movement of the wheel over the obstacle
smoothly by absorbing the shocks produced due to them. A spring is designed and produced
with due regard to all considerations, should not fail but some rare failures too may occur on a
properly designed spring.
This can be traced due to following causes:
1. Surface imperfections- Due to hardening cracks, seams, die marks etc.
2. Corrosion- A very common cause of spring failure caused by environmental

effects.
3. Improper heat treatment- It is not frequently encountered. If springs are

overheated the grain structure will become coarse and results in poor fatigue
life.
CLASSIFICATION OF SPRINGS
A variety of springs are there these days for different applications. So the springs can
also be classified as:
2
Coil Spring- A coil spring is a mechanical component used to absorb shocks or jerks
due to irregularities. These are made of elastic material which regains its actual size or
shape when unloaded. It is generally produced by winding a metal wire in the shape
of a helix. It is also called as helical spring and of following types:
■ Tension spring-Tension springs are snugly wound coils which are being used
to operate with tension. The spring stretches to produce deflection as the load is applied to
it. It’s a helical spring and requires special ends to permit application of load. These ends
assume many forms but they are not present in compression springs. A tension spring as
shown in figure 1.1(a) can be wound with initial pre-load so that it deforms only after the
load reaches a certain minimum value. Springs which are loaded both in tension
compression are rare and restricted to light duty.
(a) (b)
Figure 1.1: Tension & Compression Springs
■ Compression spring- These are open coiled helical springs in difference with
the tension springs which are also subjected to axial loading conditions. Another
difference of compression spring as shown in figure 1.1(b) with tension spring is of nature
of load applied. The axial loading conditions of the compression springs are similar to the
application of compression stress therefore they are called as compression springs.
■ Conical Spring-Conical springs are of cone shape and may be substitute of cylindrical coil
springs where axial space is limited. The conical spring as in figure 1.2(a) permit the coils
to fold into subsequent coils while the spring is completely compressed.
3
(a) (b)
Figure 1.2: Conical & Torsion Spring
■ Torsion spring-Torsion springs as in figure 1.2(b) are more compliant than

the torsion bar. A torsion spring is a spring that works against twisting effect. It
can store mechanical energy when get twisted. Basically they are closely coiled
springs with two free tangent ends to the coils.
■ Spiral spring- These are the springs produced with a metal strip or wire as shown
in figure 1.3(a) which is to be wound in a manner that the coil diameter increase in
subsequent turn, keeping all turns in same plane. Many practices are effectively
using this type of springs too. These are usually used against torque to produce an
angular deflection.
(a) (b)
Figure 1.3: Spiral & Leaf Springs
■ Leaf springs- These are the mechanical components which are frequently used in
the suspension system of automotive vehicles. These are formed with a number of
4
metal beams called leafs with gradually reducing length as shown in figure 1.3(b)
bundled together to make an assembly.
Various leaves are designed on the basis of the bending theory of beams. These may
be of different types depending upon geometry as follows:
1. Flat leaf spring- Flat leaf spring consists of one or more heat treated flat metal
bars of diminishing lengths formed to a predetermined arch held together by a bolt
through its center. If only one metal bar is there then it is called mono leaf spring while if
more than one metal bars are assembled to make a bundle then it is called multi leaf
spring. The first leaf which is of full length also called master leaf. The subsequent leaves
are called graduated length leaves because of having reducing length with stepping.
2. Multi stage leaf springs-In multi stage leaf springs two different multi leaf
springs are assembled together stating different stage. These are generally used by heavy
load vehicles like large trailers, railway wagons etc.
3. Parabolic leaf springs- This is an advanced version of multi leaf spring in

which the numbers of leaves are less as compared to flat multi leaf springs. Parabolic leaf
spring consists of special type of leaves with varying thickness from center to ends.
Secondly all leaves are of full length instead of graduated lengths. The upper surfaces of
leaves are flat while lower is tapered following a parabolic pattern. The leaves are kept in
position with the help of hard rubber tip-inserts which are also called spacers.
Figure 1.4: Flat leaf spring
5
Figure 1.5: Multi leaf spring
Figure 1.6: Multi-stage leaf spring
Figure 1.7: Parabolic leaf spring
6
In all leaf springs the master leaf is connected with the chassis of the vehicle with
eyes produced at its ends which hold the bushings through which pins pass about
which the eyes can rotate to make revolute joints. Different type of eye formations
can be formed which are as follows:
1. Standard eye- These are the most popular and easiest to make. Main plates
with Standard eyes can receive additional support by extending the second
leaf or a wrap plate.
2. Berlin eyes- These are used to minimize the tendency to unwind the eye end
against the load directed in the direction of movement. In this type load
applied through the centre line of the master leaf which reduces lateral
deflection.
3. Reverse eyes- In this type the eye ends are wrapped in reverse direction i.e.
downwards. The advantage of extra full length leaf cannot be used in this case
in comparison to standard and Berlin eyes.
Figure 1.8: Shapes of Eye Ends of a leaf spring
4. Open eye- An open eye end may also be used to connect the leaf spring with
vehicle body. The open eye as shown in photograph 1.5 looks like a C shape
hook springs which are utilized with a nylon bushing installed in the eye end.
7
Figure 1.9: Open Eye leaf spring
5. Slipper eyes- This type of eye end consists of a metallic casing fixed with the
chassis and flat end of a bunch of 2-3 full length leaves can slide inside this
casing. This casing is basically called slipper as in figure 1.5 which provides
room to the leaf end to slide during deflection.
Figure 1.10: Slipper Eye leaf spring
6. Military wrapper eye- These are generally produced for military vehicle to
provide extra protection against shocks. In this type an extra full length leaf is
used after master leaf having some special eye formation as shown in figure
8
Figure 1.11: Military Wrapper Eye leaf spring
LEAF SPRING TERMINOLOGY
With reference to leaf springs used in suspension system of automotive, there are number of
technical terms as in figure 1.8 which are necessarily known to a designer or researcher as
follows:
Datum line- It is the line from which most of the dimensions are referenced. It passes
through the centers of the eye ends.
Span- Span of a leaf spring is defined as the horizontal distance between its two eye
ends of master leaf. It is generally smaller than the actual length of the full length leaf
because of having curved profile of it.
Spring rate- Spring Rate may be defined as load per unit deflection. It can also be
stated as amount of load required to deflect a spring for a predefined value. Lower
the spring rate softer will be the spring and a softer spring results in smoother ride.
Spring rate is also known as spring constant.
9
Figure 1.12: Multi Leaf Spring Terminologies
Rated load- Rated load is the amount of weight for which the spring is designed to
carry at a certain height. It is also called design Load.
Free arc- It may be defined as the curvature of the leaf spring at no load. When the
vehicle is free or without load so that there is no deflection in the leaf spring.
Camber- Camber is the vertical height measured at the centre of the leaf spring. It is
the distance between span line and upper surface of master leaf. It can also be
represented as camber angle measured at eye ends of the full length leaf.
Stepping- Stepping is the distance from the end of one leaf to the end of the adjoining
leaf. Stepping is very important. Stepping controls the shape and strength of a spring
when under load. Too short of distance between the ends of the leaves will cause the
upper leaves to bend downward at the ends and upwards towards the centre, too long
will give the spring a wavy lock. Both conditions as shown figure 1.13 (a) & (b)
produce an ineffective spring. Stepping is critical and a correctly stepped spring can
support nearly double the amount of weight than an incorrectly stepped spring.
10
(a)
(b)
Figure 1.13: Improper Stepping of Leaf Spring
Nipping- During leaf spring assembly the full length leaf is given a greater radius of
curvature than the adjacent leaf. The radius of curvature decreases with all shorter
leaves. The initial gap provided between the extra full length leaf and graduated
length leaves before assembly as in figure 1.10 is called nip. According to previous
studies the stresses in extra full length leaves are 50% more than the stresses in
graduated length leaves. To equalizing the stress in graduated leaves pre-stressing is
required. The pre-stressing is achieved by bending the leaves to different radius of
curvature i.e. introducing nip. Such pre-stressing achieved by a difference in radius of
curvature is known as nipping.
Curvature- It is reciprocal of radius and is considered as positive in the direction in
Which increases with the intensity of load.The curvature of a flat leaf is zero and
positive curvature corresponds with negative camber.
11
Figure 1.14: Nipping of Leaf Spring
MATHEMATICAL THEORY OF LEAF SPRINGS
A flat leaf spring may have the form of a beam either a cantilever or simply supported beam
which can be considered as double cantilever beam. For its detailed mathematical analysis let us
consider a single plate of rectangular cross-section which is fixed at one end and load is applied
at the free end as shown in figure 1.11. This beam can be considered as flat spring.
Figure 1.15: Leaf as Cantilever Beam
Where, t=Thickness, b=Width, L=Length, W=Load
１２
The maximum bending moment in the cantilever beam is;
M=W×L
the section modulus of its cross section will be;
1
Z=
Y
bt2
Z=
6
and the bending stress induced due to loading can be formulate as:
M
6WL
σ = = bt2
Z
Similarly, the maximum deflection due to this point load will be produced at free end of the
beam which is;
WL2
4WL3
δ= =
3EI Ebt3
When a combination of two cantilevers is considered it will act as a simply supported beam
with length 2L and load 2W at the centre as in figure 1.12.
6WL
σ=
bt2
WL3 4WL3
σ= =
3EI Ebt3
１３
Figure 1.16: Leaf as Simply Supported Beam
If n number of plates of width w are placed in a position as shown in figure 1.17 then
the stress and deflection may be written as;
Figure 1.17: Multi Cantilever Beam
6AWL
σ=
nbt2
4WL3
δ=
nEbt3
For the purpose of analysis of a semi elliptic leaf spring, all leaves are divided into two group’s
i.e. full length leaves forming one group and graduated length leaves forming the other group.
This group of leaves can be formed through a triangular plate and assumed that the individual
leaves are separated through it keeping master leaf at centre as in figure 1.18 (a) & (b). The
graduated leaves are cut longitudinally into two halves to produce uniform width and placed
below the master leaf with to form a laminated leaf spring
１４
Figure 1.18: Quarter Leaf Spring through Triangular Plate
The stress and deflection in this case may be written as:
6WL3
δ=
nEbt3
According to the previous studies the full length leaves are having approximate 50% more
stress as compared to graduated leaves then the stresses for both can also be formulated. A
semi elliptical leaf spring can be formulated as shown in figure 1.19.
nf = number of full length leaves
ng = number of graduated length leaves
n = total number of leaves (nf+ ng)
b = width of each leaf
t = thickness of each leaf
L = half span of the leaf spring
W = load applied at the end of the spring
Wf = load taken by the full length leaves
Wg = load taken by the graduated leaves
σf = bending stress in full length leaf

１５
σg = bending stress in graduated leaves
Figure 1.19: Multi Leaf Spring through Rectangular Plate
Bending stress induced in the leaves is;
6𝑊𝐿
𝜎𝑏 =
𝑛𝑏𝑡2
the relation between stress in full length leaves & graduated leaves can be written as;
𝜎𝑓 = 3𝜎𝑔
2
which gives,
total load is divided in two segments as; W = Wg +Wƒ
load shared by full length leaves will be,
wf 3Wnf
= 3nf + 2ng
and load shared by graduated leaves,
3𝑊𝑛𝑔
𝑊𝑔 = + 2𝑛𝑔
3𝑛𝑓
Actual bending stress in full length leaves will be formulated as;
１６
18 𝑊 𝐿
𝜎𝑓 =
(3𝑛𝑓 + 2𝑛𝑔)𝑏 𝑡2
and for graduated leaves bending stress formulated as;
𝜎𝑔 =
(3𝑛 12 𝑊𝐿
+ 2𝑛 )𝑏𝑡2
𝑓 𝑔
The deflection produced in the multi leaf spring will be;
2σfL2
δ=
3Et
which becomes;
12 W L3
δ=
(3n + 2ng)E b t
2
Multi leaf springs are designed using load-stress and load-deflection equations. The standard
dimensions for the width and thickness of the leaf section are as follows:
Nominal Thickness (mm): 3.2, 4.5,5, 6, 6.5, 7, 7.5,8,9, 10, 11, 12, 14 & 16
Nominal width (mm): 32,40,45,50,55,60,65,70,75,80,90, 100 &125
Bore diameters (mm) at eye end: 19, 20, 22, 23, 25, 27, 28, 30, 32, 35, 38, 50 & 55
The leaf springs are generally manufactured by alloy steels like 65Si7, 55S6, 55Si2Mn9,
55SiMn7, 50Cr1 or 50Cr1V23, 250A53, EN45A etc. The heat treatments like hardening and
tempering are generally performed on spring steels. The factor of safety based on the yield
strength is kept between 1.5- 2 by leaf springs manufacturers.
１７
COMPUTER AIDED DESIGN
Computers are classy tools which are used for different aspect of the world to provide
precision, flexibility, competence, record keeping and decision making. In computer aided
design the computers are used to design physical objects like mechanical components or
assemblies. Computer aided design makes use of computer technology to aid design activity
particularly in drafting of a part. It is a means of communication in a particular technical field
with specific conventions. The researchers & designers who are engage in various designing
activities in different areas of engineering employ CAD systems and tools to get ready detailed
drawings with full specifications which were previously be drawn or sketched manually.
Figure 1.20: CAD Composition
Prior to introduction of CAD, manufactures and designers would require building trial products
before the testing of actual product. CAD allows the manufacturers to produce a computerized
prototype rapidly as in figure 1.16 and investigate them under a variety of simulated situations.
Recent CAE tools comprises of a variety of two dimensional drafting systems to three
dimensional solid or surface modelers. Current CAD packages are capable of various
advancements like frequent three dimensional rotation, screening of designed product from any
desired angle even from inside and any sectional cross section. For the purpose of analysis
almost all CAD packages follows a mathematical technique which is known as finite element
１８
method thus the method of analysis using these CAD software’s is also called finite element
analysis. All CAD users can also deploy this technology to optimize the system under
consideration by performance enhancement & reliability improvement. The design can be
modified and improved till the desired outcomes are achieved. This technique is fairly valuable
for prototyping as it permits the user to observe possible deficiencies before any investment on
the real product. After all above activities like drafting, analysis and optimization the final
activity is termed as documentation. This process gives the outcomes of CAD system in hard
form i.e. on paper. The drawings prepared by the CAD system along with specifications, parts
list and their costing are drawn on paper for the reference of all concerned personals who are
deployed in different departments.
Figure 1.21: Light vehicle mini truck
１９
2.LITERATURE REVIEW
The literature survey is divided into four parts: papers related to (a) leaf springs (b) parabolic
leaf springs (c) composite materials (d) shot peening. Numbers of researchers & designers
have done work on leaf springs and it is summarized as:
Leaf springs
S. Kong analysed performance of different eye design of leaf spring to avoid failure under
various driving conditions because it can cause major accidents. He simulated the leaf spring
for different conditions like braking, cornering etc. under severe loading conditions. He used
multi body dynamics model to obtain various load conditions to feed in finite element analysis.
Four distinct designs of leaf spring eyes were developed and analysed to check capability of
spring eye for different loading conditions.
Mahmud Durus investigated for fatigue life of a Z type leaf spring through testing at various
loading conditions till failure. S-N plot of components has been developed for correlation. The
strain based finite element analysis for the lea spring correlation. He performed first, second
and third correlation for durability of the leaf springs.
Jon Freire Gomez discussed about leaf spring flexure pivots requiring fatigue life
maximization. He concentrated on stress reduction for this purpose. He investigated the scope
of stress minimization through leaf shape optimization. Numbers of algorithms and
formulations have been deployed for the purpose and the improved thickness proved to be
independent of angular rotation. A nonlinear FE analysis was done for validation showing
major reductions in stresses. The improved profile was compared for various characteristics
like stiffness, strain energy etc. concluding the shape optimization as a technique of improving
fatigue life.
Farahani A.V, developed a damage parameter to observe the life of mechanical components
under variable loading conditions. He incorporated effects of materials memory, small cycles
and loading sequence on the hysteresis stress–strain loops of materials. The correlation has been
set up successfully for the life of three samples i.e. one low carbon steel and two of aluminum
alloys under variable amplitude loading spectra.
２０
Parabolic leaf springs
Michail Malikoutsakis worked with truck axle leaf springs for 7.5 to 8.0 tons. He performed
multi-disciplinary optimization of the leaf spring concentrating towards wheel joint
mechanism of automotive. Design parameters have been determined for the optimized
mechanism. The leaf spring assessment on the basis of finite element method has been done
for different conditions causing higher stress. The validation has also been done through
experimental testing of prototypes. The optimized leaf spring was evaluated by number of
expert driving personnel and found better than earlier.
Manas Patnaik worked on a parabolic leaf spring of a mini loader truck. The spring has been
analyzed to observe stress and displacement. Camber and leaf span of a parabolic leaf spring
were considered to optimize stress and displacement using artificial neural networks (ANN).
In order to study the behavior of parabolic leaf spring, variation of eye to eye distance &
camber height have been done to observe their effect on output parameters using design
of experiments (DOE).
Pratesh Jayaswal, discussed practical means for productivity enhancement with the
emphasis on rejection minimization in parabolic leaf spring manufacturing unit. In this
work method study was done for productivity improvement with the emphasis on
reduction of rejections with respect to End Gap between leaves and Camber tolerance
in leaf spring manufacturing. Mismanaged end gap was found with contribution of
27% towards rejection. Camber deviates during centre hole punching & during oil
quenching after heat treatment.
Narendra Yadav, analyzed a leaf spring whose thickness varies from centre to the outer side following a
parabolic pattern. Initially the magnitude of stress pertaining to parabolic leaf spring is computed by
finite element method and then the stress minimizing was carried out effectively with the help of Local
Algorithm. Stress minimization was taken as objective function, camber & eye distance were considered
as variables and displacement as constrain.
Composite materials
Qureshi H. A. performed a study on the analysis, design and fabrication of composite springs.
Suspension leaf spring of a car has been observed with change of material as glass fiber
reinforced plastic with similar mechanical and geometrical properties to the multi leaf spring.
The leaf spring was investigated experimentally in laboratory and also by road test.
２１
J. Yuvraj, performed analytically to investigate fundamental properties of the dimensioning of
double tapered FRP leaf spring. Among many kinds of taper configuration, i.e. double taper or
single taper configuration which again comprises triangular, trapezoidal and parabolic
configuration, the double tapered shape with linearly varying thickness, hyperbolically varying
width and constant cross section area along the length has been opted for this work to replace
steel multi leaf spring. FRP leaves were made from glass fibre and epoxy. Prototype FRP leaf
spring showed a superior endurance and fail-safe characteristics when compared with
experimental results carried out on a hydraulic spring testing machine.
Mahmood M. Shokrieh, analyzed a leaf spring of the rear suspension of a light vehicle. FEM
results were verified with analytical and experimental solutions. A composite leaf spring made
from fibre-glass with epoxy resin was designed, concentrating on optimization of the leaf
spring geometry. Compared to the steel spring, the optimized composite spring has lower
stresses, higher natural frequency and spring weight without eye units was nearly 80% lighter.
The optimum spring width decreases hyperbolically and the thickness increases linearly from
spring eye towards the axle seat.
Gulur S. Shiva Shankar, used an algorithm of C-language for the design of constant cross-
section leaf spring. A single leaf with variable thickness of unidirectional glass fiber reinforced
plastic with similar geometrical properties to the multi-leaf spring was designed, fabricated
and tested. The leaf spring was also analyzed using CAE approach for different end joints.
Shot peening
Aggarwal M.L, described that fretting between mating leaves can be eliminated by using
parabolic leaves and/or careful control of shot peening parameters. The fatigue strength and
life of parabolic leaf spring was found to be higher as compared to multi leaf spring. A
mathematical model has been developed to predict the fatigue life of leaf springs for a given
stress at varying shot peening conditions which were compared with experimental data. The
effect of shot peening intensity on fatigue life has been discussed. Shot peening of leaf spring
results, improvement in fatigue strength, reduction in weight and more reliability.
Bruno Geoffroy, described the role of shot peening in leaf springs manufacturing through the
analysis of residual stresses by X-ray diffraction and fatigue tests on a series of samples that
were subject to ten different peening schedules. Double peening until a depth of 0.02 mm
results in fatigue life improvement.
２２
Farrahi G.H, described shot peening effects such as shot hardness, shot size and shot
projection pressure, on the residual stress distribution and fatigue life of 60Sc7 spring steel. A
curve for residual stress distribution has been plotted to correlate between fatigue strength and
area under the residual stress distribution curve. The biggest shot shows the best fatigue life
improvement. While a shorter time of shot peening and small hard shot results in best
performance.
Andrews Scott, concentrated on effect of roughness characteristics of machined surfaces on

fatigue life using a series of computer simulations. The roughness characteristics like asperity
heights, distance between asperities, asperity radii and initial crack sizes are considered to
account for the presence of intrinsic defects. The growth rate of multiple cracks were
determined as a function of stress amplitude and crack length accounting for local stress fields
from the asperities, crack closure effects, and crack interaction. In all simulations the crack
growth constants were systematically varied with suitable normalization of results and the
model resulted with satisfactory predictions of fatigue lives.
２３
3.METHODOLOGY
INTRODUCTION
Fatigue design or designing against fatigue failure, may have the objectives of infinite life,
zero weight, infinite strength or 100% reliability – or perhaps all four simultaneously. It is
essential that the optimized design parameters from computer aided analysis of leaf springs
must be validated through experimental testing. This will assist in reliable prediction of design
parameters from computer model for various geometry and materials of leaf springs.
COMPUTER AIDED ENGINEERING
CAE is the use of information technology for supporting engineers in tasks such as analysis,
simulation, design, manufacture, planning, diagnosis and repair. Software tools that have been
developed for providing support to these activities are considered as CAE tools. CAE tools are
being used to study the robustness and performance of mechanical components and assemblies.
It encompasses simulation, validation and optimization of different products and
manufacturing tools. In future CAE system will be the major information providers to support
professional designers and researchers in decision making. CAE embraces the application of
computers from preliminary design i.e. computer aided design proceeded by production i.e.
computer aided manufacturing as shown in figure 3.1. Computer aided design (CAD) is
usually associated with computerized drafting applications and also includes such diverse
applications to calculate dimensional stack-ups due to tolerances, ergonomic studies with
virtual people and design optimization. CAE analysis includes finite element method for
solving the partial differential equations governing solid mechanics, fluid mechanics and heat
transfer. Computer aided manufacturing (CAM) include programs for generating the
instructions for computer numerical controlled machining for production, process scheduling,
quality and inventory control. The complete procedure of CAE can be illustrated as integration
of various activities which are component designing, its analysis, production and controlling.
The design phase is consists of need of design, detailed specifications and collection of other
relevant information followed by feasibility study of the conceptual design. The second phase
which is analysis phase includes stress calculation on the basis of predefined boundary &
loading conditions and if required on the basis of all calculations the optimized model can be
produced. These two phases comes under the umbrella of CAD i.e. computer aided design.
２４
CAD
CAE
CAM
Figure 3.1: CAD - CAM - CAE Relationship
Afterwards the computer aided manufacturing i.e. CAM comes in action which
encompasses two stages planning & production and control. The third phase comprises
optimized scheduling of various manufacturing processes which are required to be
performing followed by component manufacturing with computer numeric controlled
machine tools. The fourth phase embraces various control activities like inventory
control and quality control.
CAE Software Packages
The following CAE tools have been used for this research work:
 CATIA V5 –R 17
 ANSYS-11 WORKBENCH
２５
CATIA is famous for its interactive user interface and leader in the field of CAD modeling. As
far as analysis is concern CATIA can also done the analysis but while dealing with complex
geometries it is sometimes difficult. On the other hand CAE analysis can be performed using
ANSYS WOKBENCH with incredibly effortless because of having its specialty in the
respective domain.
CATIA
Computer Aided Three Dimensional Interactive Application i.e. CATIA is a technical

platform of computer aided engineering applications introduced by D assault systems a French
company. The CATIA user interface for two dimensional & three dimensional modeling along
with toolbars are shown in figure 3.2 & 3.3 respectively.
Figure 3.2: Two Dimensional Tool Bars of CATIA
The software package is written in a computer language named C++. The software was
created in the late 1970’s and early 1980’s to develop D assault's Mirage Fighter jet by
French manufacturer Avions Marcel and later chosen by other aerospace, automotive,
shipbuilding industries. Dassault systems helped its industrial customers to improve
their product design and development. Afterwards the legend of aircraft industry i.e.
２６
Boeing Company decided to use CATIA in 1984 as their major CAE tool becoming
the leading customer.
Impressing from its popularity with number of industrial giants, in 1990 CATIA was
adopted by General Dynamics Electric Boat Corp as their principal tool to design
Navy's submarine for US. European aerospace giant Airbus is also using CATIA since
2001. Later on numerous versions of CATIA has been released periodically till date.
The latest edition launched in 2014 is CATIA on Cloud which is a cloud version of this
package. Numbers of automotive companies who are using CATIA as their designing
tool are BWM, Audi, Volvo, Fiat, Benteler AG, Toyota, Honda, Ford, Scania, Hyundai,
Proton, Tata motors and Mahindra. CATIA is very good in surface creation and
computer representation of surfaces. Its capabilities are applicable to a variety of
industries such as aerospace, automotive industrial machinery, electrical, electronics,
shipbuilding, plant design, and consumer goods
Figure 3.3: Three-Dimensional Tool Bars of CATIA
ANSYS Workbench
ANSYS, a three-dimensional CAE tool, was developed by US based company ANSYS Inc. It
is an entirely dedicated tool for finite element analysis of engineering systems. ANSYS is
２７
termed as the standard in the field of computer aided engineering modeling & analysis. The
software package was introduced in 1970 by Swanson Analysis Systems Inc, i.e. SASI. They
developed their trade in parallel with the expansion of computer technology and engineering
requirements. In 1994 TA Associates became the owner of SASI and designated the flagship
as ANSYS Inc. worldwide. The graphical user interface of ANSYS facilitates to work with
three dimensional components and generate required graphical outcomes. Using ANSYS a
variety of tasks can be performed like structural analysis, fluid dynamics analysis, heat flow
analysis and complete product optimization. The finite element analysis using ANSYS
workbench can be performed through the following three main phases:
Pre-processor: The pre-processor is a program that processes the input data to produce the
output in form of data files. The input data required to be fed are in the form of distinct
categories like type of analysis, geometric model, meshing, material properties, loading and
boundary conditions etc.
Solution: The output of first phase which is pre-processors is taken as input to this phase
which is solution phase. This phase generates the element matrices & computes nodal values
and stores result data in numerical form.
Postprocessor: The output of solution phase is fed to third phase which is postprocessor which
processes the result data and displays them in graphical form to check and analyse. It is the
most important step of an analysis in order to understand how the applied loads affect the
design. Post processor shows various target outcomes like contour geometry, deformed shapes,
applied forces and moments, nodal displacements, stress contour, Von- Mises stresses and
principal stresses.
CAE ANALYSIS
In CAE technique the finite element analysis (FEA) is a procedure to obtain approximate
solution to the boundary value problems of engineering. It works following a numerical
technique termed as finite element method (FEM). Earlier the design professionals were used
FEM for structural analysis by manual calculations for their problems which was later
replaced by CAE tools and made it possible to work out speedily with more accuracy. These
days most of the designers engaged in R&D sectors are using these tools for effective &
efficient outcomes. In general, to be more familiar with FEA helps us to construct models with
greater accuracy. The equilibrium equation specified by FEM technique may be written as:
２８
F= K∗U
Here [F] is load matrix, [K] is stiffness matrix and [U] is deflection matrix in which K
is a square matrix while U and F both are column matrices. Some of the important
FEA terminologies which are necessary to keep under consideration before
proceeding are nodes, elements, element type, meshing, DOF, material properties,
loading & boundary conditions, etc.
FEA PROCEDURE IN ANSYS
In ANSYS the complete analysis procedure can be divided in to three phases which
are termed as pre-processor, solution and postprocessor. To conduct the finite element
analysis, it is required to follow the sequence of above said phases. The first phase is
pre-processor in which numbers of inputs are to be imported to makeup the
required environment under which the component works in realistic world. First of all
it is required to define type of analysis in this phase i.e. weather it is a structural
analysis or non-structural analysis. Structural analysis may include static analysis,
dynamic analysis, modal analysis, harmonic analysis, spectrum analysis and buckling
analysis. The static analysis deals with the constant loading conditions while the
dynamic analysis is used to determine response to non-constant time varying loads.
Modal analysis helps to determine natural frequencies of the structures while
harmonic analysis observes response to harmonically time varying loads. Spectrum
analysis turns out in response to random vibrations while the buckling analysis comes
in action against buckling loads to determine the buckling shape of structures. On the
other hand, non-structural analysis may have thermal analysis, fluid flow analysis or
electromagnetic analysis. After defining type of analysis next is to create or import a
geometrical CAD model. Afterwards it is necessary to set up a relationship between
all mating parts of the geometry so that a proper connection among all can be
established. Later on material properties are to be considered after defining the
material to be used. The material properties of a substance are responsible to clarify
about that how it will react with external conditions. All materials own different
properties and may react in dissimilar tradition under given situations. As far as
design of a component is concerned the behaviour of materials with respect to
external forces is to be observed which requires the mechanical properties of material.
Every material under influence of a load results with deformation, yielding or failure
２９
according to intensity of load. In ANSYS there is a material library which consists of
all of the engineering materials along with their material properties. The FEA flow in
ANSYS is shown in figure 3.4.
TYPE OF ANALYSIS
STRUCTURAL ANALYSIS NON-STRUCTURAL ANALYSIS

(STATIC OR DYNAMIC)
GEOMETRY
CREATE/IMPORT PART CONTACT/ MATERIAL
MODEL CONNECTION PROPERTIES
MESHING
DISCRETIZATION
TYPE OF ELEMENT MESH CONTROL
(NODES & ELEMENTS)
LOADING CONDITIONS
TYPE OF LOADING LOAD APPLICATION
BOUNDARY CONDITIONS
DEGREE OF
CONSTRAINTS ASSUMPTIONS
FREEDOM
SOLUTION
MATRIX
GENERATION COMPUTATION STORING VALUES
GRAPHICAL REPRESENTATION
RESULT DISPLAY INTERPRETATION
Figure 3.4: FEA Flow Chart of ANSYS
３０
4.MODELING IN CATIA V5
CATIA stands for Computer Aided Three-dimensional Interactive Application. It is a

multi-platform CAD/CAM/CAE commercial software suite developed by the French
company Dassault Systems, technically supported worldwide by IBM. Also, CATIA is the
most powerful knowledge based and widely used CAD (computer aided design) software
of its kind in the world. The most commonly CATIA users are generally Aerospace,
Appliances, Architecture, Automotive, Construction, Consumer Goods, Electronics,
Medical, Furniture, Machinery, Mould and Die, and Shipbuilding industries.
In this study, CATIA V5 is taken as the primary CAD system not only
because of the power and versatility but also due to the increasingly large market share that
is being gained by CATIA V5.
4.1 DESIGN OF A LEAF SPRING
３１
Figure 4.1: Design of Leaf spring
３１
5.STATIC ANALYSIS OF LEAF SPRING
A group of numerical methods for approximating the governing equations of any
continuous system is known as Finite Element Analysis (FEA).
Example of problems that can be treated by FE:
• Structural Analysis
• Heat Transfer
• Fluid Flow
• Mass Transport
• Electromagnetic Potential
• Acoustic
In this study, analysis of an is done using Static analysis. Static analysis is a part of FEA
and it has been carried out using ANSYS work bench software.
ANSYS
ANSYS is a general-purpose software, used to simulate interactions of all

disciplines of physics, structural, vibration, fluid dynamics, heat transfer and
electromagnetic for engineers. So ANSYS, which enables to simulate tests or working
conditions, enables to test in virtual environment before manufacturing prototypes of
products. Furthermore, determining and improving weak points, computing life and
foreseeing probable problems are possible by 3D simulations in virtual environment. Also,
it can work integrated with other used engineering software on desktop by adding CAD
and FEA connection modules.
ANSYS can import CAD data and also enables to build geometry with its
"pre-processing" abilities. Similarly in the same pre-processor, finite element model (a.k.a.
mesh) which is required for computation is generated. After defining loadings and carrying
out analyses, results can be viewed as numerical and graphical. It can carry out advanced
engineering analyses quickly, safely and practically by its variety of contact algorithms,
time-based loading features and nonlinear material models.
ANSYS Workbench is platforms which integrate simulation technologies

and parametric CAD systems with unique automation and performance. The power of
３２
ANSYS Workbench comes from ANSYS solver algorithms with years of experience.
Furthermore, the object of ANSYS Workbench is verification and improving of the
product in virtual environment.
Non-linear static analysis

Static Analysis provides the calculation for the stress state of structures under
forces which are constant in terms of time. To date probably this is the most demanded
task in the design. By using the module "Static analysis," the engineer can evaluate the
allowable stresses in design which is developed, determine drawbacks of the design and
make necessary changes (optimize) the product. Static studies calculate displacements,
reaction forces, strains, stresses, and factor of safety distribution. Static analysis can help
you avoid failure due to high stresses. Various structural loads and restraints can be
specified including force, pressure, gravity, rotational load, bearing force, torque,
prescribed displacement, temperature, etc
Static analysis also allows to:
 Take the geometric into non-linearity
 Determine the stress-strain state of temperature effect
 Perform calculations of contact problems
Main results of static analysis are as follows:
 Field of displacements of the structure in nodes of finite-element mesh
 Field of strain
 Field components of the stress
 Energy of deformation
 Nodal forces
 Field distribution of safety factor
This information is usually sufficient to predict the behaviour of structures and make a
decision how to optimize the geometric shape of the product.
Non-linear behaviour:
A structure is a nonlinear if the loading causes significant changes in stiffness.
 Strains beyond the elastic limit

３３
 Large deflections
 Contact between two bodies
Analysis flow chart:

The flow chart of the process using Computer Aided Engineering (CAE) tools is as follows:
 Computer modelling, mesh generation Pre-Processor

 Definition of materials properties.
solver
 Assemble of elements
 Boundary conditions and loads defined
 Solution using the required solver

Post-processor
and display results/data
5.3.1. Steps are involved in the procedure
1. Divide / discretize the structure or continuum into finite elements. This is typically
done using mesh generation program, called pre-processor. Tetrahedral (solid187) element
captures complete behaviour of components by creating appropriate mathematical model
during analysis.
Figure 5.1 Mesh generation
2. Formulate the properties of each element.
３４
Ex.: Nodal loads associated with all elements, deformation states that are allowed.
Figure 5.2 Stress vs Strain
3. Assemble the elements to obtain the model
4. Specify the load and boundary conditions. Constraints, force, known temperatures, etc.
5. Solve simultaneous linear algebraic equations to obtain the solutions.
5.4 DEFINE in ANSYS

. In order to accurately model the deformations of the, non-linear finite-element
procedures are need to be employed. With the advent of the development of contact
analysis, it is appropriate to apply the contact analysis technique in the analysis. Thus, the
effect of the system with contact has been studied.
Tasks to be done ANSYS:

1. Each part in the component has to be capable of holding both tensile and compressive
loads successively.
2. Stresses and deflection should be within the permissible limits.
3. Perfect contact pair should be formulated.
4. Parts of the component should always be bonded to each other.
5. Converges of the model should be achieved.
Solution Methods Adopted: In Step-1: Firstly, the CATIA V5 CATPART file

should be imported into ANSYS 16.2 for doing static analysis.
Step-2: The imported model should be assigned with element type and material properties.
Step-3: Now the model should be meshed with desired mesh shape.
３５
Step-4: After meshing checking the contact pairs should be assigned to the different parts
of the model.
Step-5: Contact status should be checked, boundary conditions and load of 18000N is
applied.
Step-6: Solve the model for getting stresses, deflections, etc.
ANALYSIS PROCEDURE
LAUNCHING ANSYS WORK BENCH
Click on Start menu and select ANSYS work bench 16.2, then a window will be opened
then click on static structural as shown in the below figure 5.3.
Fig 5.3: Ansys workbench 16.2 window
PRE PROCESSING (Setting up the model)
Our analysis is a Static Structural analysis. It can be found in the Toolbox on the left,
and needs to be added to the Project Schematic by either double clicking it, or by
dragging it into the panel.
３６
Fig 5.4: Static structural panel
The Static Structural component and all of its modules will be created. The modules are
similar to those in ANSYS MAPDL. They outline the steps that are required to complete a
finite element analysis.
◆ Engineering Data module is used to define the material properties.
◆ Geometry module opens the Design Modeler application, which can be used to import
CAD models from other software like Solidworks or to sketch a new 2D or 3D
geometry.
◆ Model, Setup, Solution, and Results modules opens the Mechanical application, which
can be used to set up and solve the simulation (includes meshing, load and boundary
condition applications, solving, and results).
ENGINEERING DATA
Double-click Engineering Data. What you see in this window may differ from the
screenshot below. In here, you can add a new material by defining a new material entry for
Structural Steel, Carbon fiber, E Glass epoxy, S Glass epoxy, Kevlar epoxy.
◆ By selecting Engineering data option, the window will be opened as shown in above
figure 5.5. we have selected the materials (Structural steel, Carbon fiber, E Glass
epoxy, S glass epoxy, Kevlar epoxy) from the library of materials.
３７
◆ After selecting materials, we have to enter the properties of materials (Young’s
modulus & Poisson's ratio) that we have selected.
Table -5.1: Material properties of steel leaf spring
Density(g/cm^3) 7.85
Young modulus (MPa) 2.0 E+05
Poisson’s ratio 0.3

Bulk modulus (MPa) 1.667E +05
Shear modulus (Mpa) 7.69 E +04
Tensile Strength(Mpa) 4.6E+02
Table -5.2: Material properties of carbon fiber
Young modulus (MPa) 5.25 E+05
Bulk modulus (MPa) 2.8646e+005
Shear modulus (Mpa) 1.0261e+005
Tensile Strength(Mpa) 2900
Table-5.3: Material properties of E glass epoxy
Young modulus (MPa) 80000
Bulk modulus (MPa) 4.59E+04
Shear modulus (Mpa) 3.30E+04
Table-5.4: Material properties of S glass epoxy
Young modulus (MPa) 89000
３８
Table-5.5: Material properties of Kevlar epoxy
Young modulus (MPa) 1.36E+05
Fig 5.5: Selection of engineering data
◆ Exit Engineering Data by closing the tab at the top of the window and return to the
main Project.
IMPORTING THE MODEL OF LEAF SPRING
For importing the designed CATIA leaf spring model into ANSYS workbench click on
‘geometry’ option from static structural panel. In this we can either import already
designed model or we can design in this window by clicking design molder application.
３９
Fig 5.6: Imported CATIA leaf spring model
MESHING
Similar to that of ANSYS MAPDL, meshing will resolve the model into elements and
nodes that will resemble the geometry. The arrangement of these elements and nodes is
known as a mesh. As you may have figured out from Assignment 1, the mesh can have an
effect on the results of the analysis. A finer mesh typically gives more accurate results, but
at the cost of higher computational requirements. Other mesh factors, such as shape,
element order and distribution, may also influence the accuracy of your results.
For meshing of the component click on the ‘model’ option from the static structural panel.
In this we can apply mesh .we have applied mesh with the help of “hyper mesh”software
and given the element size as 100, and a fine mesh has been applied. The shape of mesh is
tetrahedral mesh. The below figure 5.7 shows the meshed leaf spring.
(a) Detailed view
４０
(a) Full view
Fig 5.7: Meshed leaf spring
Workbench provides different selection tools that will allow you to select vertices, edges,
faces, and bodies. To switch between these, use the buttons at the top of the screen. You
also have the option to interact directly with the geometry or the mesh by using the drop
down menu for Select Type (Geometry/Mesh).
Fig 5.8: Tool bar options for meshing
APPLYING BOUNDARY CONDITIONS & LOAD
Before applying the load on the leaf spring we should apply boundary conditions to the
spring for getting accurate results as same as the real life conditions. In this leaf spring the
eye end of one side is fixed in all directions.
For applying boundary conditions right click on static structural in the tree or in the static
structural panel in project schematic window. Then click on insert > click on fixed support
option then select the surface or the object to be fixed as shown in the figure 5.9.
４１
Fig 5.9: Applying boundary conditions
A load of 8000 N is applied on the lower side of the leaf spring. The procedure for
applying load is as shown in the below figure 5.10.
◆ “Outline” pane > Model > Static Structural (right-click) > Insert > Force > Click on
Face > “Details” pane > Scope > Geometry > Apply.
◆ “Details” pane > Definition > Magnitude > Type 8000N.
◆ “Outline” pane > Model (right-click) > Insert > Symmetry.
◆ “Outline” pane > Model > Symmetry (right-click) > Insert > Symmetry Region >
Click on left edge > “Details” pane > Scope > Geometry > Apply
４２
Fig 5.10: Applying force
POST PROCESSING (SOLUTION)
In post processing we can get the results applied for the load. In this project we are going
to find the results of Total deformation, Equivalent stress & strain developed in the spring.
These results can be obtained as shown in the below figure.
Fig 5.11: solution total deformation

４３
Fig 5.12: solving equivalent stress
Fig 5.13: Solving equivalent strain
By clicking solve by right clicking on the solution option we get the results as shown in the
results chapter.
４４
6.RESULTS AND DISCUSSIONS
We analysed floor cleaner structure in ANSYS 16.2 and finding out Von misses
stress, strain and total deformation by using different materials at different loading
conditions as show in below figures and then resulting all the max values of every material
and are compared in the form of graphs.
Static Analysis
LOADING OF LEAF SPRING: We observe Von-Mises stress and Von-Mises strain and
Total deformation for loading of leaf spring material under four different materials are
Carbon fibre , Structural Steel, Kevlar, S Glass, E Glass.
Results of Carbon fiber leaf spring
Fig 6.1: Carbon fibre Deformation
Fig 6.2: Carbon fibre Equivalent stress
４５
Fig 6.3: Carbon Fibre Equivalent strain
Table -6.1: Carbon fiber leaf spring results
Carbon fiber leaf spring Minimum Maximum
Total Deformation(mm) 0 0.0843
Equivalent Stress(Mpa) 1.905e-6 128.21
Equivalent Strain 6.574e-12 0.000259
Results of Conventional steel leaf spring
Fig 6.4: Conventional steel Leaf spring Deformation
４６
Fig 6.5: Conventional steel Leaf spring stress
Fig 6.6: Conventional steel Leaf spring strain
Table -6.2: conventional steel leaf spring results
Conventional steel leaf spring Minimum Maximum
４７
Results of E Glass epoxy leaf spring
Fig 6.7: E Glass deformation
Fig 6.8: E Glass Equivalent Stress
Fig 6.9: E Glass Equivalent Strain
４８
Table -6.3: E Glass epoxy leaf spring results
E Glass epoxy leaf spring Minimum Maximum
Equivalent Stress (Mpa) 9.348e-7 130.6
Results of S Glass epoxy leaf spring
Fig 6.10: S Glass deformation
Fig 6.11: S Glass Equivalent stress
４９
Fig 6.12: S Glass Equivalent Strain
Table -6.4: S Glass epoxy leaf spring result
S Glass epoxy leaf spring Minimum Maximum
Results of Kevlar epoxy leaf spring
Fig 6.13: Kevlar deformation
５０
Fig 6.14: Kevlar Equivalent stress
Fig 6.15: Kevlar Equivalent strain
Table -6.5: Kevlar leaf spring result
Kevlar leaf spring Minimum Maximum
５１
COMPARISON OF RESULTS
Table -6.6: Result comparison of all leaf springs
Leaf spring material Total Deformation Equivalent stress Equivalent elastic strain
Carbon fiber 0.1843 128.21 0.000259
Steel Leaf spring 0.2206 128.82 0.000706
E Glass epoxy 0.5509 130.6 0.00191
S Glass epoxy 0.49549 130.61 0.0017202
Kevlar epoxy 0.213 119.58 0.000891
Results Comparison Table
５３
Weight Calculation:
Let us consider the weight of single leaf
Mass = Density x (Volume) in Kg
Weight of steel spring =7850 (0.003) = 23.55 kg
1. Weight of E-Glass/Epoxy spring =2600 (0.003) = 7.8kg

% of Less Weight = 100 – (Wt. of E-Glass/Epoxy Leaf Spring ÷ Wt. Of Steel Leaf Spring) x100
= 100 – (7.8÷ 23.55) x 100 = 66.87%
2. Weight of S-Glass/Epoxy spring =2490 (0.003) = 7.47kg

% of Less Weight = 100 – (Wt. of S-Glass/Epoxy Leaf Spring ÷ Wt. Of Steel Leaf Spring) x100
= 100 – (7.47÷ 23.55) x 100 = 68.3%
3. Weight of Carbon spring =2000 (0.003) = 6kg

% of Less Weight = 100 – (Wt. of Carbon Leaf Spring ÷ Wt. Of Steel Leaf Spring) x100
= 100 – (6÷ 23.55) x 100 = 74.67%
4. Weight of Kevlar spring =1440 (0.003) = 4.32kg

% of Less Weight = 100 – (Wt. of Kevlar Leaf Spring ÷ Wt. Of Steel Leaf Spring) x100
= 100 – (7.8÷ 23.55) x 100 = 81.7%
５３
7.CONCLUSIONS
A comparative study has been made between conventional multi leaf steel spring and
composite leaf spring of S glass epoxy, carbon fibre, E glass epoxy, Kevlar epoxy with
respect to deflection. Among these Carbon fibre and Kevlar 49 has the better results but
Expensive.Both E-Glass and S-Glass are Good Results Nearer to Base Material and Using
Of These Material Reduce the overall weight of Leaf Spring. Use of these materias for leaf
spring reduces the friction co efficient and wear rate and increase the strength, fatigue life
by over conventional multi leaf steel spring.
A comparative study has been made between steel and different materials for leaf
spring with respect to strength and weight. Among these materials Steel leaf spring
weights higher weight and Kevlar 49 weight lower ,use of Kevlar material for Leaf Spring
lo and reduces the weight by 81.7%
５３
6. REFERENCES
[1] Mr. Mangesh Angadrao Bidve, Dr. Manish Billore. “Review on design optimization
and analysis of composite leaf spring for light weight vehicle” GORTERIA Journal
(2021)
[2] Priyanka Kothari, Amit Patel.”A Review paper on Design and Analysis of Leaf spring”
International Journal of Engineering Research & Techonology(IJERT) (2014)
[3] Dasari Ashok Kumar, Abdul Kalam SD. “Design, Analysis and Comparison between
the conventional Materials with Composite Material of the Leaf spring” Fluid
Mechanics: Open Access (2016)
[4] Mayur D. Teli, Umesh S. Chavan, Haribhau G. Phakatkar “Design, Analysis and
Experimental Testing of Composite Leaf Spring for Application in Electric Vechile”
International Journal of Innovative Technology and Exploring Engineering (IJITEE).
(2019).
[5] Mr. Mayur H. Karpe, Mr. Shubham P. Korde, Mr. Tushr S. Shinde, Ms. Surekha S.
Sangale. “Performance Analysis of Composite Leaf Spring” International Advanced
Research Journal in Science, Engineering and Techonology (IARJSET) (2017).
[6] E.P.Shanmugham, R. Meijazhagan, S. Karthikeyan. “Static Analysis of Leaf Spring
with Heterogeneous Concept” International Journal of Innovative Trends in
Engineering (IJITE) (2015).
[7] Prasad P. Kunzarkar, Prof. Tushar V. Gujarathi. “A Review on Automotive Car
Composite Leaf Spring Design and Optimization” International Journal of Recent
Development in Engineering and Techonology (IJRDET) (2018).
[8] V.R.Baviskar, P.L.Sarode, I.N.Wankhede, N.P.Salunke. “Static Analysis of Master
Leaf Spring” International Journal of Research in Engineering and Techonology
(IJRET) (2014).
[9] Rupesh N.Kalwaghe, Prof.K.R.Sontakke. “Design and Analysis of Composite Leaf
spring by using FEA and ANSYS” International Journal of Scientific Engineering and
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DESIGN AND ANALYSIS OF A LEAF SPRING

FOR LIGHT VEHICLE MINI TRUCKS

In the present scenario weight reduction is the main focus of an automobile

LIST OF FIGURES viii

CHAPTER 1: INTRODUCTION 1-19

INTRODUCTION OF SPRINGS 1-2

CLASSIFICATIONS OF SPRINGS 2-8

LEAF SPRING TERMONOLOGY 8-11

MATHEMATICAL THEORY OF LEAF SPRINGS 11-16

COMPUTER AIDED DESIGN 17-18

CHAPTER 2: LITERATURE REVIEW 20-23

CHAPTER 3: METHODOLOGY 23-30

COMPUTER AIDED DESIGNING 23-24

CAE SOFTWARE PACKAGES 24-30

3.3.1 CATIA 25-26

FEA PROCEDURE IN ANSYS 28-30

CHAPTER 4: MODELING IN CATIA V5 31

CHAPTER 5: STATIC ANALYSIS OF LEAF SPRING 32-38

NON LINEAR STATIC ANALYSIS 33-34

Nonlinear behavior 33-34

ANALYSIS FLOW CHART 34

Steps involved in procedure 34

TASK TO BE DONE IN ANASYS 35

SOLUTION METHODS ADOPTED 35

ANALYSIS PROCEDURE 36-43

LAUNCHING ANSYS WORKBENCH 36

PRE PROCESSING (SETTING UP THE MODEL) 36-37

ENGINEERING DATA 37-38

IMPORTING THE MODEL OF LEAF SPRING 39

APPLYING BOUNDARY CONDITIONS & LOAD 41

POST PROCESSING (SOLUTION) 43

CHAPTER 6: RESULTS AND DISCUSSION 45-52

RESULTS OF CARBON FIBER LEAF SPRING 45

RESULTS OF E GLASS EPOXY LEAF SPRING 48

RESULTS OF S GLASS EPOXY LEAF SPRING 49

RESULTS OF KEVLAR EPOXY LEAF SPRING 50

CHAPTER 8: REFERENCES 54-55

Figure 1.1: Tension & Compression Springs 3

Table -5.1: Material properties of steel leaf spring 38

Following are the different applications of springs:

1. To provide cushioning effect by absorbing unwanted energy produced due to

2. To exert force in brakes, clutches and various valves.

3. To control motion between two elements as in cam and followers.

4. To measure force in spring balances, engine indicators etc.

5. To store energy in different mechanical devices like watches & toys.

This can be traced due to following causes:

1. Surface imperfections- Due to hardening cracks, seams, die marks etc.

2. Corrosion- A very common cause of spring failure caused by environmental

3. Improper heat treatment- It is not frequently encountered. If springs are

Figure 1.1: Tension & Compression Springs

Figure 1.2: Conical & Torsion Spring

■ Torsion spring-Torsion springs as in figure 1.2(b) are more compliant than

Figure 1.3: Spiral & Leaf Springs

3. Parabolic leaf springs- This is an advanced version of multi leaf spring in

Figure 1.4: Flat leaf spring

Figure 1.6: Multi-stage leaf spring

Figure 1.7: Parabolic leaf spring

Figure 1.8: Shapes of Eye Ends of a leaf spring

Figure 1.10: Slipper Eye leaf spring

LEAF SPRING TERMINOLOGY

Figure 1.13: Improper Stepping of Leaf Spring

Curvature- It is reciprocal of radius and is considered as positive in the direction in

positive curvature corresponds with negative camber.