PROJECT REPORT

VIJAY ANAND.P.G
121332201016
M.Tech. Design Engineering (Part Time)
Dr. MGR
Educational and Research Institute.
university

MODELING AND ANALYSIS

OF MONO LEAF COMPOSITE
SPRING

Introduction
A

leaf spring is a simple

suspension spring commonly
automobiles.

type of
used in

The advantages of leaf spring over helical

spring is that the ends of the spring be

guided along a definite path as it deflects
to act as a structural member in addition
to energy absorbing device.

Construction of leaf spring

Leaf springs used in automobiles is of

Semi-

Elliptical in form.
It is built up of number of plates(known as leaf) ,
which are of reducing lengths.
The longest leaf is called main leaf or Master leaf,
And the other leaves are called as graduated
leaves.
The spring is clamped to the axle by means of Ubolts.
Rebound clips are used to hold the leaves together.
Central clamp is used to fix the position of leaf
spring to the wheel axle.

Construction of leaf spring

Principle of Leaf Spring

Leaf spring work on the principle

of bending. When the load is

applied at the ends bending
occurs.
Naturally,
structure
opposes bending. This results in a
reaction force which opposes the
load applies. There by we get the
spring property of the leaf spring.

Material Used for Leaf Spring

The materials used for leaf springs is usually a

plain carbon steel having 0.90 to 1.0% carbon.

According
to
Indian
Standards
the
Recommended Materials are:

For Automobiles : 50 Cr 1 , 50 Cr 1 V 23 ,
55 Si 2 Mn 90 ,60Si7 used in
Hardened and Tempered state.

For Rail Road Springs : C 55(waterHardened ,

C 75-Oil hardened) , 40 SI 2 Mn
90 (Water Hardened) and 55 Si 2 Mn 90 (Oil
hardened)

Disadvantages in Steel Springs

Weight is more High Density of Steel.
Material and Process cost is high.
Design Complexity.
High Wear and Tear
Cracking sound during operation.
Frequent need of Maintenance.
Life is less.
Fuel efficiency affected due to weight.
Corrosive nature.

Scope of the project

Leaf Spring
Material
Composite

Steel
Modeling
Analysis
Compare

Recommend Suitable
Material

Soft wares used for

Modelling & Analysis

For modeling PRO E 5.0 was

used
For analyzing ANSYS 14.5 was

used

WHAT IS COMPOSITE ?
Composite Materials consist of fibers of

high strength and modulus embedded

in or bonded to a matrix with distinct
interfaces between them.
They have combination of properties of
both fiber and matrix
It is a heterogeneous mixture of matrix,
fiber and other constituents.
The primary property is high strength to
weight ratio.

PROPERTIES OF COMPOSITE
High strength to weight ratio
Good fatigue strength and damage tolerance
Properties are direction dependent
Low coefficient of thermal expansion
Tailor-able properties
Orthotropic nature
High damping quality
Non-corrosive
No need of secondary manufacturing pro cesses

Less manufacturing cost

Mono leaf composite spring

Now-a-days automotive industries are trying to
reduce the weight
and increase the strength
of leaf spring for efficient suspension.
Composite spring is the best material suitable
for the above required criteria.
This material has less weight and high strength
when compared to the materials using in the
leaf springs using in nowadays leaf springs.

Why Composite Spring ?

1) Specifically made to give effects like Air Suspension with out
any extra external energy(Fuel)
2) No permanent deformation hence no re-cambering, thus no
maintenance.
3) Minimum wear and tear of body parts and tyre due to delicate
tendency of absorbing road shocks, jerks and vibrations.
4) Softer ride, Lower noise level, excellent stability due to better
damping characteristics.
5) Excellent corrosion resistance against atmospheric pollutants.
6) Five times stronger than conventional metal leaf springs.

7) Fully interchangeable with the

conventional spring without any modifications.
8)Increase in fuel efficiency due to better
aerodynamics and around 60% weight
reduction.
9) No cracking sound since mono leaf and
hence no inter-leaf friction and no greasing
required.
10) Fatigue life 1 million cycles as compared
to only 2 lacks for the metal leaf springs.

Methodology carried out

Data collection
Modeling of steel spring in PRO E 5.0
Import the model to ANSYS in IGES

format
Analyzation by ANSYS 14.5
Save the results
Selection of matrix and fibres with
suitable property
Modeling of Mono leaf spring by PRO E
Analyzation by ANSYS 10.0

Methodology carried out (Contd.)

Save the results
Compare both steel and composite

analysis results
Analyze and Conclusion

COMPOSITE MATERIAL
ANALYZED

E-Glass Fiber/Epoxy

Load Acting on Leaf Spring

Ambassador BS IV
Kerb Weight : 1000 Kg
Load carrying capacity: 450 Kg
Gross Weight : 1450 Kg
Factor of Safety : 1.15
Acceleration by Gravity: 9.8 m/s2
Model Choosed:

Total Weight : 1450x1.15x9.8 = 16341 N

For Single Spring = 16341/4 = 4085 N
Therefore Load on the Spring : 4000

(App).

Dimensions of Leaf Spring

Material used
: 55 Si 2 Mn 90
Length of Master Leaf :

1200mm
Free Camber
: 200mm
Thickness
: 6mm
Width
: 50mm

Model of
Leaf Spring by PRO E

THANK YOU