Alexandria Engineering Journal (2023) 73, 109–121

H O S T E D BY
Alexandria University

Alexandria Engineering Journal

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ORIGINAL ARTICLE

ANSYS based analysis of multi-level parabolic leaf

spring systems
_ ßci b
Mehmet Bahadır Çetinkaya a,*, Muhammed Is

a
Department of Mechatronics Engineering, Faculty of Engineering, University of Erciyes, Kayseri 38039, Turkey
b
Department of Mechatronics, Technical Sciences Vocational School, University of Kayseri, Kayseri 38280, Turkey

Received 1 March 2023; revised 15 April 2023; accepted 22 April 2023

Available online 3 May 2023

KEYWORDS Abstract Leaf spring systems are mechanical structures used to attenuate or absorb the disruptive
Multi-level parabolic leaf factors such as stress, strain, deflection and deformation occurring on dynamic systems. Leaf spring
spring system; systems may produce different responses to external forces depending on their geometric structures
Modal analysis; and material properties. Computer-aided analysis of leaf spring systems is crucial in determining the
Pressure analysis deformation properties and structural properties of the system with high accuracy. In this work, the
10-7, 10-5 and 8-7 multi-level parabolic steel leaf spring systems were analyzed by ANSYS Work-
bench 18.1 software. In the simulations, the total deformation values emerging under the pressure
values of 12.5 Pa, 25.0 Pa and 37.5 Pa and the resonance frequency values for 20 different mode
shapes were obtained. The simulation results represent that the highest deformations occur in 8-7 leaf
spring system at all pressure values. Furthermore, as a result of the modal analyzes it was observed
that the resonance frequencies of 10-7, 10-5 and 8-7 leaf spring systems were respectively occurring at
the intervals of [143.17 Hz, 520.89 Hz], [143.98 Hz, 511.4 Hz] and [146.58 Hz, 525.21 Hz].
Ó 2023 THE AUTHORS. Published by Elsevier BV on behalf of Faculty of Engineering, Alexandria
University. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/
licenses/by-nc-nd/4.0/).

1. Introduction striking occurring during the movement of the dynamic system

Leaf spring systems are structures produced from high-
strength and flexible materials in order to enhance the load
carrying capacity of mechanical systems. The leaf spring sys-
tems which are one of the most basic components of the auto-
motive industry are also widely used in different industrial
applications to attenuate or completely absorb the effects of
external forces. The external forces of braking, cornering and
* Corresponding author.
E-mail address: cetinkaya@erciyes.edu.tr (M.B. Çetinkaya).
Peer review under responsibility of Faculty of Engineering, Alexandria
University.
https://doi.org/10.1016/j.aej.2023.04.043
1110-0168 Ó 2023 THE AUTHORS. Published by Elsevier BV on behalf of Faculty of Engineering, Alexandria University.
This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/).
cause pressure affects on the system and the lifetime of the
whole system may reduce due to the malfunctions occurring
as a result of these pressure affects. In addition, these pressure
affects may also cause other undesirable effects such as stres-
ses, strains, deflections and surface deformations over the sys-
tem. In order to obtain the detailed deformation properties
and structural properties of the dynamic system to be
designed, pressure analysis and modal analysis should be per-
formed, respectively.
Leaf spring systems constitute the most important part of
the suspension systems in the automotive industry. These sys-
tems are designed by gradually combining a certain number of
leaf springs each of different lengths [1] and can also be used
110
for weight reduction in vehicles [2,3]. Due to their crucial
importance in automotive industry, the leaf spring systems
have become an active area of research in recent years. The leaf
spring systems analyzed in this work are mostly used in trucks,
trailers, work machines and farm machineries which are
exposed to high intensity disruptive external factors. In addi-
tion, they can also be used in light commercial vehicles due
to their flexible structures.
In the literature, there are restricted number of works
related to detection of external forces affecting to the leaf
spring system with high accuracy. In [4], Çetinkaya and Is _ ßci
have improved artificial neural network-based estimators in
order to analyze the vibration effects on leaf spring systems.
In their work [5], Jung et al. have realized a detailed fatigue
analyzes to determine the fatigue strength of leaf spring struc-
tures with different geometries. In order to increase the load
carrying capacity of leaf spring systems, ANSYS based ana-
lyzes have also been realized to examine the importance of
material selection and design geometry. In [6] presented by
Shaikh et al., the fatigue life cycle ratios of leaf spring sys-
tems having different geometric structures were analyzed via
ANSYS software by taking into account the thickness and
the number of the leaves. In work [7] presented by Amsalu
and Damtie, the numerical analyzes under static load for
both mono and multi level steel leaf springs and laminated
carbon/epoxy composite materials were carried out by using
the Solidworks and ANSYS Workbench 18.1 softwares. In
work [8], Arora et al. performed computer aided design
and analysis of a conventional leaf spring system under dif-
ferent experimental and prestress conditions. In another work
presented by Satasiya et al. [9], the performances of compos-
ite materials used in the design of leaf spring systems were
compared by using ANSYS software. In a similar ANSYS
based work presented by Ekbote et al. [10], the stress and
deflection results obtained for a steel leaf spring system
including 9 leafs have been analyzed by using the Finite Ele-
ment Method (FEM). In another material analysis based
work presented by Bhanage and Padmanabhan [11], the fati-
gue properties of a steel leaf spring system and a composite
leaf spring system made of glass/epoxy material were com-
pared by using ANSYS Workbench 14.0. Shamim and Anwer
presented a ANSYS FEM based work which consists of the
design and comparative analyzes of a multi-leaf spring system
made of AISI 6150 Steel, Ti-6Al-4V Composite and S-Glass
Fiber Composite materials [12]. In work [13], Chauhan
et al. have developed polymer (epoxy) based composites in
order to investigate the flexural strength and wear behavior
of leaf spring systems produced for light commercial vehicles.
Shokrieh and Rezaei realized the ANSYS V5.4 based ana-
lyzes of a four-leaf steel leaf spring system used in the rear
suspension system of light vehicles and then they designed
a composite made of fiberglass with epoxy resin according
to the results obtained [14]. In another related work, the
deformations and stresses occurring on a leaf spring system
under both static and dynamic prestress conditions have been
investigated by Elsheltat et al. [15]. Kumar and Subhash have
designed a leaf spring bracket in CATIA V5 software and
analyzed its performance by using ANSYS software in order
to minimize the stresses occurring under different load condi-
tions [16]. In the literature, there are also modal analysis
based studies in order to determine the distortion modes of
_ ßci
M.B. Çetinkaya, M. Is
leaf spring systems and to estimate its resonance frequency.
Rao and Venkatesh performed ANSYS based modal analyzes
of leaf spring systems designed with four different composite
materials (E-glass/epoxy, graphite/epoxy, carbon/epoxy and
Kevlar/epoxy) and then determined the resonance frequencies
of each structure [17]. Material based analyzes were realized
via CATIAVR9 and ANSYS softwares by Tadesse ve Fatoba
to compare the theoretical and FEM analysis of coated com-
posite leaf spring structures in terms of enhanced Von Mises
Stress and better deflection [18]. In their work [19], Balakr-
ishna ve Mishra realized ANSYS based static analyzes and
modal analyzes using the finite element method to determine
the stress, deformation and weight reduction parameters.
Shrivastava et al. in [20] presented detailed analyzes for the
design process of an E-Glass leaf spring system by using
the CAD and ANSYS software. In [21], Borhade and Patti-
war determined the resonance frequency of a single leaf
spring both experimentally with fast Fourier transform
(FFT) analyzer and theoretically by using FEM with ANSYS
software. Saianuraag and Sivaram performed detailed ana-
lyzes using Unigraphics NX7.5 and ANSYS 11.0 to predict
the behavior of composite leaf spring and compare its perfor-
mance to that of steel leaf spring [22]. In work [23] presented
by Juliyana et al., a mono composite leaf spring system with
varying thickness and varying width was analyzed in terms of
static linear and modal analysis results. In [24], the design
and ANSYS based analysis of Carbon/Epoxy based compos-
ite single leaf spring was presented by Ravindra et al. for the
aim of weight reduction in the automobile industry. Finally,
in work [25] by Gowd and Goud, the authors applied FEM
analysis to determine the safe stresses and pay loads of the
leaf spring system at which a comfortable and safe drive is
possible.
As seen from the literature review, there are a certain num-
ber of works related to ANSYS based analysis of leaf spring
systems consisting of material analysis, geometric analysis,
force analysis, pressure analysis and modal analysis. However,
to our best knowledge, the characteristics of multi-level para-
bolic leaf spring systems under different pressure values and
the resonance frequencies for different Mode shapes will be
simultaneously analyzed for the first time within the scope of
this work.
The main contributions of this work to the literature can be
summarized as follows:

The deformations occurring as a result of the pressure val-
ues of 12.5, 25 and 37.5 Pascal applied to the 10-7, 10-5 and
8-7 multi-level parabolic steel leaf spring systems were
obtained through ANSYS based analyzes and the results
presented to the literature.

ANSYS based modal analyzes were performed for different
geometric structures of each leaf spring system and the res-
onance frequencies obtained for each mode were
determined.

Static and dynamic analyzes were carried out simultane-
ously for both upper and lower leaf spring systems of a
multi-layer leaf spring system. The effects of the increases
or decreases in the number of lower and/or upper layer
leaves on stress, total deformation and resonance frequen-
cies were analyzed simultaneously and in conjunction with
each other.
ANSYS based analysis of multi-level parabolic leaf spring systems

The simulation results obtained for the leaf spring systems
analyzed will provide a detailed database for leaf spring sys-
tem manufacturers and researchers, especially in the auto-
motive industry.
The rest of this paper is organized as follows. Section 2 is
presenting detailed reviews about the analyzed multi-level
parabolic steel leaf spring systems and the analysis methods
applied. In Section 3, simulations were carried out in order
to obtain the total deformation results emerging under dif-
ferent pressure values and the resonance frequency values
occurring for different mode shapes. The relevant conclu-
sions and discussions are presented in Section 4 and
Section 5.
2. Material and method
Leaf spring systems are the dynamic suspension equipments
designed to attenuate or completely absorb the external forces
of different types and intensity that dynamic systems exposed.
Pressure and deformation analysis with high precision have to
be carried out on leaf spring systems before mass production.
The pressure analysis is performed to predict the physical
deformations that may occur in the system for predetermined
conditions. On the other hand, modal analysis is a crucial
approach which reveals the structural properties of dynamic
systems.
In this work, ANSYS based pressure and modal analyzes
have been carried out on a steel leaf spring system developed
and designed within the scope of [26] by the authors in coop-
eration with Daimler Mercedes Aksaray/Turkey factory. This
multi-level parabolic leaf spring system having double bushes,
named as 10-7 leaf spring system, consists of 10 leaves in the
upper leaf spring system and 7 leaves in the lower leaf spring
system. In order to present a more fair and realistic results,
in addition to the 10-7 leaf spring structure, the 10-5 and 8-7
leaf spring structures have also been analyzed. The 10-5 leaf
spring structure was obtained by reducing two leaves from
the lower part of the 10-7 structure. Similarly, two leaves were
reduced from the upper part of the 10-7 structure in order to
obtain the 8-7 leaf spring structure. In the ANSYS based pres-
sure and modal analyzes, the resonance frequencies and also
the maximum deformations occurring under different pressure
values of 10-7, 10-5 and 8-7 leaf spring structures were
obtained and compared.
The general structure and basic components of a multi-level
parabolic leaf spring system having double bushes are shown
in Fig. 1.
In Fig. 2, the front and top views of the technical drawings
of the 10-7, 10-5 and 8-7 steel leaf spring systems analyzed
within the scope of this work are given. In the technical draw-
ings, the regions denoted by S forms the lower part of the
multi-layer leaf spring system, On the other hand, the section
placing above the S region forms the upper part of the system.
A, B, C and M values are taken as standard values for all
designs. A represents the distance between the two bushes of
the upper leaf spring system, B defines the diameter of the cen-
ter bolt to which pressure applied, C denotes the width of each
flat leave and finally M can be determined as the thickness of
each flat leave. The geometric properties of the leaf spring sys-
tems analyzed are given in Table 1.
111
Fig. 1 General structure and basic components of a multi-level
parabolic leaf spring system.
Modal analysis is also an effective approach used to analyze
the limits of the responses produced by a dynamic system. One
of the most common usage area of the modal analysis is the
detection of resonance frequency. Resonance frequency of a
dynamic system defines the frequency value at which the
amplitude distortions began to occur at the system output.
On the other hand, the concept of Mode can be defined as
the shape of a dynamic system takes while it is vibrating at
the resonance frequency. The main purpose of analyzing the
Mode shapes and resonance frequency is to prevent a dynamic
system from being forced at the resonance frequency and the
frequencies close to it by updating the design structure. In this
work, firstly, the pressure analyzes for each of the 10-7, 10-5
and 8-7 leaf spring structures have been realized by using
ANSYS Workbench 18.1 and then modal analyzes have been
carried out to determine the resonance frequency and optimal
Mode shape. Each of the 10-7, 10-5 and 8-7 leaf spring struc-
ture were analyzed according to Mode 1, Mode 2, Mode 3,
Mode 4, Mode 5 and Mode 6 structures.
In order to reduce the physical complexity of the leaf spring
system, prior to both pressure analysis and modal analysis, the
Finite Element Method (FEM) was applied for the purpose of
cutting the system into smaller elements at points called nodes.
The FEM model of the 10-7 leaf spring system consists of
44,485 elements and 135,125 nodes, the FEM model of the
10-5 leaf spring system consists of 43,882 elements and
131,381 nodes, and finally the FEM model of the 8-7 leaf
spring system consists of 43,542 elements and 129,359 nodes.
In the ANSYS based analysis of the leaf spring systems,
meshing procedure constitutes one of the most important ele-
ments of the design process. The value of the Element Size
parameter was taken as 7.7  103 in the MESH processes per-
formed for each of the 10-7, 10-5 and 8-5 geometric structures.
On the other hand, the Body Number parameter values for
each of the 10-7, 10-5 and 8-5 geometric structures were taken
as 18, 16 and 16, respectively. The meshing images obtained
for each of the 3 leaf spring structure were shown with Fig. 3.
In the simulations, each leaf spring system was fixed from
the regions indicated by the flag A in Fig. 4 and then the pres-
sure analyzes were performed by applying pressure to the Cen-
ter Bolt region which was represented by flag B. Also, the red
arrow in Fig. 4 represents the direction of the pressure applied.
In both pressure analysis and modal analysis the material
property is a crucial factor. In this work, ANSYS based pres-
112
Fig. 2 Technical drawings of the 10-7, 10-5 and 8-7 leaf spring systems analyzed in this work.
sure and modal analyzes were realized for the leaf spring sys-
tems designed by the Structural Steel material available in
ANSYS material library. The detailed material properties of
the structural steel preferred in this work are given in Table 2.
3. Simulation results
In order to achieve maximum efficiency in the design process
of dynamic systems, performing modal analyzes prior to actual
design is extremely important for the designer. In this work,
firstly, the pressure values of 12.5, 25 and 37.5 Pa were applied
_ ßci
M.B. Çetinkaya, M. Is
to the predetermined regions of the 10-7, 10-5 and 8-7 leaf
spring structures and the total deformations occuring were
analyzed by using ANSYS software. In addition, the response
of each leaf spring structure to the prestresses occurring due to
pressure was also analyzed separately. Afterwards, ANSYS
based modal analyzes were carried out on a leaf spring system
to determine the instant frequency values at which amplitude
distortions began to occur at the system output.
Fig. 5 (a) represents the pressure applied region and the
fixed support regions of the designed 10-7 leaf spring structure.
The total deformation characteristic of the leaf spring system
for 12.5 Pa pressure value is given in Fig. 5 (b). It is seen that
ANSYS based analysis of multi-level parabolic leaf spring systems 113

Table 1 Geometric properties of the leaf spring systems

analyzed.
Geometric Properties
Length of flat leaves, L Upper Flat Lower Flat
Leaves Leaves
L1 = 200 mm L11 = 140 mm
L2 = 260 mm L12 = 140 mm
L3 = 360 mm L13 = 240 mm
L4 = 480 mm L14 = 410 mm
L5 = 560 mm L15 = 470 mm
L6 = 720 mm L16 = 660 mm
L7 = 820 mm L17 = 660 mm
L8 = 920 mm
L9 = 1000 mm
L10 = 1000 mm
Distance between two 990 mm
bushes, A
Diameter of the center bolt, 14 mm
B
Width of each flat leave, C 57 mm
Thickness of each flat leave, 8 mm
M

the prestreses that emerge as a result of 12.5 Pa pressure value

cause maximum deformation especially at the pressure applied
region and at the lower leaf spring system. Fig. 5 (c) demon-
strates the results obtained for the 25 Pa pressure value. The
results represent that when the pressure value was increased
to two times of the initial pressure, the maximum deformation
value affecting to the leaf spring system also increase propor-
tionally. Finally, the ANSYS result obtained for the 37.5 Pa
pressure value was given in Fig. 5 (d). It can be stated from
the results that when the pressure value is increased to its high-
est value of 37.5 Pa, the maximum deformation value increases
approximately as three times of the initial deformation value.
The ANSYS based modal analysis results obtained for the
designed 10-7 leaf spring system are shown in Fig. 6 below. Fig. 3 Meshing process for the 10-7, 10-5 and 8-5 geometric
The simulations were realized for six different modes. The structures.
Mode 1 modal analysis result given in Fig. 6 (a) represents that
the relevant leaf spring structure produces the resonance fre-
quency as 143.17 Hz. In addition, it is also seen that the defor-
mations are concentrated especially in the upper part of the
leaf spring system. From the Mod 2 analysis result at which
the resonance frequency was obtained as 250.15 Hz, it was
determined that possible deformations will be concentrated
especially in the edge regions of the lower leaf spring system.
When the Mode 3 analysis result which has the resonance fre-
quency of 270.17 Hz and given in Fig. 6 (c) examined, it can be
stated that deformations will occur especially at the lower leaf
spring system for the relevant mode structure. In Mode 4 anal-
ysis represented in Fig. 6 (d), the resonance frequency was Fig. 4 The fixed support and pressure applied regions of the leaf
obtained as 320.33 Hz. It was also observed that medium spring systems analyzed.
intensity deformations will occur in the upper and lower leaf
spring systems while higher intensity deformations will emerge
in the edge regions of the lower leaf spring system. Finally, was seen that the deformations frequently will occur in the
Fig. 6 (e) and Fig. 6 (f) represent the Mode 5 and Mode 6 anal- lower leaf spring systems.
ysis results, respectively, and the value of the resonance fre- The second leaf spring system analyzed in this work was
quencies were obtained as 374.44 Hz and 520.89 Hz. In leaf obtained by reducing the number of leaf springs to 5 in the
spring system structures corresponding to Modes 5 and 6, it lower leaf spring system. The pressure applied region and the
114 _ ßci
M.B. Çetinkaya, M. Is

In general, it can be concluded that maximum deformation

Table 2 Properties of steel material used in the design of leaf
occurring for each pressure value is concentrated in the pres-
spring systems analyzed in this work.
sure applied region and the lower leaf spring system.
Material Type Property Value The modal analysis results obtained for the 10-5 leaf spring
Structural Steel Density 7850 kg/m3 system are shown in Fig. 8 below.
Poisson’s Ratio 0.3 When the Mode 1 analysis result given in Fig. 8 (a) is exam-
Young’s Modulus 2e+11 Pa ined, the resonance frequency value produced by the system is
Bulk Modulus 1.6667e+11 Pa observed as 143.98 Hz. It is also seen for Mode 1 analysis that
Shear Modulus 7.6923e+10 Pa both 10-7 and 10-5 structures produce similar results in terms
Tensile Yield Strength 2.5e+8 Pa of the maximum deformation. Fig. 8 (b) represents the Mode 2
Tensile Ultimate Strength 4.6e+8 Pa
analysis result for which the resonance frequency is obtained
as 273.67 Hz. As seen from the figure, the lower leaf spring sys-
tem is exposed to more structurally deformation when com-
pared to 10-7 leaf spring structure. The Mode 3 deformation
characteristics of the 10-5 leaf spring system given in Fig. 8
fixed support regions of the 10-5 leaf spring structure is shown (c) indicates that the system reaches to the resonance at
in Fig. 7 (a). In Fig. 7 (b), the simulation results obtained for 289.81 Hz. On the other hand, a decrease in the maximum
12.5 Pa is demonstrated. It is seen that the deformation regions deformation value has also been observed when compared to
are the same as the 10-7 structure, but the maximum deforma- 10-7 leaf spring structure. In the Mode 4 analysis, where the
tion affecting on the leaf spring system increases. Fig. 7 (c) rep- resonance frequency is obtained as 322.96 Hz, it is seen that
resents the analysis results obtained when the pressure value the deformations are concentrated especially in the lower leaf
applied is increased to 25 Pa. It can be stated that when the spring system and this region is structurally forced. The anal-
pressure value applied to the system is increased, the regional ysis results obtained for Mode 5 and Mode 6 are shown in
deformation intensities occurring on the system will also Fig. 8 (e) and Fig. 8 (f), respectively. As seen from the figures,
increase proportionally. Finally, the simulation results the resonance frequencies are obtained as 382.42 Hz and
obtained for 10-5 structure and 37.5 Pa pressure value are 511.40 Hz. For the Mode 5 analysis, it can be expressed that
shown in Fig. 7 (d). It is seen that the maximum deformation the value of the resonance frequency increased when compared
value measured is similar but a bit higher when compared to to the 10-7 structure, but the maximum deformation value
10-7 structure although the number of lower leaf springs is remains almost the same. Finally, for both Mode 5 and Mode
reduced to five. 6 analysis, it is seen that the lower leaf spring system exposed

Fig. 5 The pressure regions and the total deformation results of 10-7 leaf spring system. (a) The pressure applied region and the fixed
support regions, (b) The deformation results obtained for 12.5 Pa, (c) The deformation results obtained for 25 Pa, (d) The deformation
results obtained for 37.5 Pa.
ANSYS based analysis of multi-level parabolic leaf spring systems
Fig. 6 The modal analysis results of 10-7 leaf spring system. (a) Mode 1, (b) Mode 2, (c) Mode 3, (d) Mode 4, (e) Mode 5, (f) Mode 6.
to more deformation when compared to 10-7 structure at res-
onance frequencies.
The third leaf spring system analyzed in this work was
obtained by reducing the number of leaf springs to 8 in the
upper leaf spring system. In Fig. 9 (a), pressure applied region
and the fixed support regions of the 8-7 leaf spring system is
represented. When the 12.5 Pa pressure is applied to the sys-
tem and the results compared to that of 10-7 and 10-5 leaf
spring structures, it has been observed that deformation
regions remains the same, but the maximum deformation value
increased compared to the other two structures. It has also
seen that the effect of two leaf springs reduced from the upper
leaf spring system on deformation is greater than the effect of
two leaf springs reduced from the lower leaf spring system. The
analysis results obtained under the conditions of 8-7 structure
and 25 Pa pressure and given in Fig. 9 (c) demonstrate that the
115
8-7 leaf spring system has exposed to more deformation than
the other two leaf spring system structures. It is also seen that
the intensity of the deformation is concentrated in the pressure
applied region and the lower leaf spring system depending on
the increasing pressure value. As a result, it can be concluded
that all three leaf spring system structures produce similar
deformation behaviors under the 25 Pa pressure. The analysis
results obtained under the pressure of 37.5 Pa are given in
Fig. 9 (d). It has been observed that deformations with higher
intensity occur on the 8-7 system due to the two leaf springs
reduced in the upper leaf spring system. In general, it can be
stated that higher maximum deformations occur at all pressure
values in the 8-7 leaf spring system when compared to 10-7 and
10-5 structures. Finally, the regions where the deformations
concentrated are obtained as the pressure applied region and
the lower leaf spring system.
116
Fig. 7 The pressure regions and the total deformation results of 10-5 leaf spring system. (a) The pressure applied region and the fixed
support regions, (b) The deformation results obtained for 12.5 Pa, (c) The deformation results obtained for 25 Pa, (d) The deformation
results obtained for 37.5 Pa.
The modal analysis results obtained for the 8-7 leaf spring
system are shown in Fig. 10 below. From the Mode 1 analysis
result given in Fig. 10 (a), it can be expressed that higher defor-
mation will occur in the lower leaf spring system compared to
the 10-7 structure due to the reduction of the number of upper
leaf springs. However, when compared to 10-5 structure, it can
also be concluded that 8-7 structure produces lower deforma-
tion on the whole system. Finally, the resonance frequency
value for Mode 1 analysis is obtained as 146.58 Hz. In the
Mode 2 and Mode 3 analysis, where the resonance frequency
values were obtained as 263.57 Hz and 266.12 Hz, it was
observed that deformations occurred in similar regions for
all three leaf spring system. Also, the maximum deformation
value obtained for the Mode 3 analysis of the 8-7 structure
was found to be higher than the relevent deformations occur-
ring in the other two structures. Fig. 10 (d) shows the simula-
tion result for the case Mode 4. In the Mode 4 analysis of 8-7
structure, where the resonance frequency was obtained as
310.95 Hz, it was observed that the deformations were concen-
trated on the lower leaf spring system, as in the other two
structures. In the Mode 5 and Mode 6 analyzes given in
Fig. 10 (e) and 10 (f), the resonance frequency values were
obtained as 371.18 Hz and 525.21 Hz, respectively. It is seen
for both Mode 5 and Mode 6 that the maximum deformation
characteristics that occur on the 8-7 system are similar to the
characteristics obtained in 10-7 and 10-5 structures.
In order to present a more clear representation the maxi-
mum deformation values that occur under the pressure values
_ ßci
M.B. Çetinkaya, M. Is
applied were combined in Table 3. For each leaf spring struc-
ture, it is seen that the maximum deformation value affecting
on the system changes proportionally with the pressure value
applied.
In order to present a more fair and detailed comparison,
Table 4 represents the proportional relationship occurring
between the pressure value and the total deformation due to
the changes in the number of upper or lower leaf springs. In
the 8-7 leaf spring system obtained by reducing the number
of upper leaf springs of the 10-7 structure, approximately %
19.350 increase was observed in the total deformations occur-
ring in all pressure values. On the other hand, for the 10-5
structure obtained by reducing the number of lower leaf
springs of the 10-7 leaf spring system, an avarage of % 0.045
increase was observed in the total deformations occurring in
all pressure values. As a result, it has been observed that the
strength of the system decreases approximately 433 times when
the number of upper leaf springs is reduced by two leaf springs.
However, it has been also observed that reducing the number
of leaf springs in the lower leaf spring system has much less
effect on the system strength.
Finally, Table 5 shows the proportional relationship
occurring between the Modes and the resonance frequencies
due to the changes in the number of upper or lower leaf
springs. As seen from the results given for 8-7 leaf spring sys-
tem, the resonance frequencies increased for the modes of
Mode 1, Mode 2 and Mode 6. Namely, the system become
more strength for the geometric structures represented by
ANSYS based analysis of multi-level parabolic leaf spring systems
Fig. 8 The modal analysis results of 10-5 leaf spring system. (a) Mode 1, (b) Mode 2, (c) Mode 3, (d) Mode 4, (e) Mode 5, (f) Mode 6.
these three modes. However, the decreases observed in the
resonance frequencies for the Mode 3, Mode 4 and Mode 5
shows that the system become less strength in the related
mode structures. When the results given in Table 5 for the
10-5 structure examined, it has been observed that the system
exhibits similar behaviors for each mode except Mode 6. It
was seen that reducing the number of leaf springs in the
lower leaf spring system leads an increase in resonance fre-
quencies for the modes between Mode 1-Mode 5. However,
a decrease in resonance frequency was observed in the geo-
metric structure represented by Mode 6. At the same time,
it can be concluded that the highest increase in the resonance
frequency value was also appeared in the Mode 2 geometric
structure.
In this work, firstly, the ANSYS based modal analyzes were
carried out in detail for each of the first 6 Modes and the res-
117
onance frequency values obtained were presented. In order to
present more detailed results to the literature, the modal ana-
lyzes were also performed for the next 14 modes. In conclu-
sion, the resonance frequency values obtained for the first 20
modes of the 10-7, 10-5 and-8-7 structures were combined in
Table 6.
From the table, it can be stated that the 10-5 leaf spring sys-
tem generally produces higher resonance frequencies to that of
the other two structures. In a general manner, it can be
expressed that the leaf spring structures producing higher res-
onance frequency values are able to provide a more strength
geometry in terms of deformation when compared to other
structures.
The relationship between the modes and the resonance fre-
quencies for each of the 10-7, 10-5 and 8-7 structures are com-
pared in Fig. 11. As seen from the figure, the resonance
118
Fig. 9 The pressure regions and the total deformation results of 8-7 leaf spring system. (a) The pressure applied region and the fixed
support regions, (b) The deformation results obtained for 12.5 Pa, (c) The deformation results obtained for 25 Pa, (d) The deformation
results obtained for 37.5 Pa.
frequency values produced at modes by each geometric struc-
ture seems close to each other.
In order to present detailed results in terms of material
strength, Von Mises Stress analysis has also been carried
out. This maximum distortion criteria determines the design
limits of a material and if it meets long life test standards or
not. As mentioned previously all the pressures have been
applied directly to the Center Bold region. Considering that
the surface area of the Center Bolt region is 212.08 mm2, the
force equivalents of 12.5 Pa, 25 Pa and 37.5 Pa pressure values
in Newton are obtained as 26.51  104N, 53.02  104N and
79.53  104N, respectively. The maximum Von Mises Stress
values corresponding to the relevant forces are given separately
in Table 7 for each of the 3 geometric structures.
When the Von Mises Stress values given in Table 7 exam-
ined, it was observed that the highest stress values were emerg-
ing in the 10-5 geometric structure. On the other hand, the
stress effects with lower amplitudes obtained for the 10-7 leaf
spring system represent that the relevant structure is more
resistant to the external forces. Finally, it has also been
observed that a linear relationship is occurring between the
force applied to the system and the stress value emerging due
to the relevant force.
4. Discussion
Computer-aided analysis of disruptive factors such as stress,
strain, deflection and deformation caused by pressure effects
in mechanical systems has become an important area of
_ ßci
M.B. Çetinkaya, M. Is
research in recent years. ANSYS based analysis as one of the
most important computer-aided approaches enables the detec-
tion of disruptive factors emerging due to the pressure effect
with higher accuracy before the real-time design.
In this work, firstly, the design of three different multi-
level parabolic steel leaf spring systems were realized via
Solidworks software. Afterwards, the total deformation ana-
lyzes occurring due to the pressure effect and the modal
analyzes for different geometric structures were realized by
using ANSYS software. When the pressure analysis results
examined, it can be expressed that the total deformation val-
ues emerged for 8-7 leaf spring system seem a bit higher
than the other two structures in all working conditions.
From the modal analysis results obtained for all working
conditions, it was observed that higher resonance frequency
values were generally obtained for 10-5 leaf spring system.
Although the lowest resonance frequency values were gener-
ally obtained for the 8-7 structure, it was also observed that
the highest resonance frequency value obtained among all
simulations was emerged in the Mode 6 analysis of 8-7
structure. Higher resonance frequency values indicate that
the relevant dynamic system is more strength to the external
forces. Consequently, the pressure analysis and modal anal-
ysis results represent that reducing the number of leaf
springs in the upper leaf spring system leads system to
expose more deformation. Similarly, it has also been
observed that reducing the number of leaf springs in the
lower leaf spring system will cause a higher deformation
effect on the system.
ANSYS based analysis of multi-level parabolic leaf spring systems 119

Fig. 10 The modal analysis results of 8-7 leaf spring system. (a) Mode 1, (b) Mode 2, (c) Mode 3, (d) Mode 4, (e) Mode 5, (f) Mode 6.

Table 3 The maximum deformation values occurring under Table 4 The proportional relationship occurring between the
the pressure values applied. pressure value and the total deformation due to the changes in
Structure (Leaf Spring Pressure Maximum the number of upper or lower leaf springs.
System) Value Deformation Structural Change Pressure Value Effect Ratio
(Pascal) (Meter) (Pascal) (%)
10-7 12.5 2.6016e11 Upper Leaf Springs (2 leaf 12.5 19.349
25.0 5.2032e11 springs reduced) 25.0 19.349
37.5 7.8047e11 37.5 19.351
10-5 12.5 2.6028e11 Lower Leaf Springs (2 leaf 12.5 0.0461
25.0 5.2055e11 springs reduced) 25.0 0.0442
37.5 7.8083e11 37.5 0.0461
8-7 12.5 3.105e11
25.0 6.21e11
37.5 9.315e11
120 _ ßci
M.B. Çetinkaya, M. Is

Table 5 The proportional relationship occurring between the Modes and the resonance frequencies due to the changes in the number
of upper or lower leaf springs.
Structural Change Mode Shape Effect Ratio (%)
Upper Leaf Springs (2 leaf springs reduced) Mode 1 2.381 "
Mode 2 5.364 "
Mode 3 1.499 ;
Mode 4 2.928 ;
Mode 5 0.870 ;
Mode 6 0.829 "
Lower Leaf Springs (2 leaf springs reduced) Mode 1 0.565 "
Mode 2 9.402 "
Mode 3 7.269 "
Mode 4 0.821 "
Mode 5 2.131 "
Mode 6 1.821 ;

Table 6 Resonance frequency values in Hertz obtained for the first 20 modes.
10-7 10-5 8-7 10-7 10-5 8-7
Mode 1 143.17 143.98 146.58 Mode 11 1183.3 1184.4 1203.7
Mode 2 250.15 273.67 263.57 Mode 12 1270.3 1274.8 1232.7
Mode 3 270.17 289.81 266.12 Mode 13 1353.1 1366.2 1399.2
Mode 4 320.33 322.96 310.95 Mode 14 1585.0 1546.4 1590.3
Mode 5 374.44 382.42 371.18 Mode 15 1740.5 1734.3 1749.3
Mode 6 520.89 511.40 525.21 Mode 16 1908.1 1914.1 1908.0
Mode 7 540.93 536.08 537.85 Mode 17 2342.1 2356.7 2226.4
Mode 8 811.07 832.20 812.23 Mode 18 2410.7 2449.1 2386.7
Mode 9 953.61 962.05 953.73 Mode 19 2628.5 2623.5 2608.3
Mode 10 1004.6 1008.90 961.23 Mode 20 2685.3 2691.5 2656.3

Fig. 11 The variation of resonance frequency according to mode values.

ANSYS based analysis of multi-level parabolic leaf spring systems 121

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