ISSN: 2395-0560

International Research Journal of Innovative Engineering

www.irjie.com
Volume1, Issue 5 of May 2015

Design, Fabrication and Testing of Mono Composite Leaf

Spring for Light Motor Vehicle
Umeshkumar M Loliyana
M.E., Design Engineering Student,

Dr. L G Navale
Professor in Mechanical Engineering, Department of Mechanical Engineering, Puna University,
Dr. D. Y. Patil Institute of Engineering & Technology, Pimpri, Pune-411018, India

Abstract- Unique property high strength to weight ratio of fiber reinforced spring has drawn the attention of manufacturers in automobile
industry. A single leaf with variable thickness and width for constant cross sectional area of unidirectional glass fiber reinforced plastic(GFRP)
is considered for analysis and subsequently for replacement of steel spring considering identical performance. The objective is to compare the
carrying capacity, stiffness and weight saving of mono composite leaf spring with that of steel leaf spring with view to replace. The comparison
of performance parameters of mono composite GFRP leaf spring. With steel leaf spring is carried out to assess its suitability for replacement in
light motor vehicles. Model is fabricated and tested. The solid model of the leaf spring was made in Creo parametric and the analysis was done
using ansys 14.0.
Keywords-Convectional leaf spring; mono composite leaf spring; glass fiber reinforced plastic (GFRP);Creo parametric;ansys 14.0

I.

INTRODUCTION

In order to conserve natural resources and economize energy, weight reduction has been the main focus of automobile
manufacturer in the present scenario. Weight reduction can be achieved primarily by the introduction of better material, design
optimization. Mono leaf springs are simple forms of springs, commonly used for the suspension system in wheeled vehicles.
Vehicle suspension system is made out of springs that have basic role in power transfer, vehicle motion and driving.
The suspension leaf spring is one of the potential items for weight reduction in automobile as it accounts for ten to twenty
percent of the unsprung weight. This helps in achieving the vehicle with improved riding qualities. The automobile industry tends
to improve the comfort of user and reach appropriate balance of comfort riding qualities and economy .There is increased interest
in the replacement of steel leaf spring with composite leaf spring due to high strength to weight ratio.

Fig. 1

Stress strain curves for composite and conventional steel.

The stress strain curves for the composites and conventional steel are shown in the figure-1.

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ISSN: 2395-0560

International Research Journal of Innovative Engineering

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Volume1, Issue 5 of May 2015

II.

MATERIALS

A. SELECTION OF MATERIAL [1]

Material of the leaf spring should consist of nearly 6-7% of the vehicle cost and contribute to the quality and the
performance of the vehicle. Even a small amount in weight reduction of the vehicle, may have a wider economic impact.
Composite materials are proved as suitable substitutes for steel in connection with weight reduction of the vehicle. Hence, the
composite materials have been selected for leaf spring design.
B. FIBERES SELECTION
The commonly used fibers are carbon, glass, keviar, etc.
Among these, the glass fiber has been selected based on the cost factor and strength. The types of glass fibers are C-glass, S-glass
and E-glass. The C-glass fiber is designed to give improved surface finish. S-glass fiber is design to give very high modular,
which is used particularly in aeronautic industries. The E-glass fiber is a high quality glass, which is used as standard
reinforcement fiber for all the present systems well complying with mechanical property requirements. Thus, E-glass fiber was
found appropriate for this application.
C. RESINS SELECTION
In a FRP leaf spring, the inter laminar shear strength is controlled by the matrix system used, Since these are reinforcement
fibers in the thickness direction, fiber do not influence inter laminar shear strength. Therefore, the matrix system should have
good inter laminar shear strength characteristics compatibility to the selected reinforcement fiber. Many thermo set resins such as
polyester, vinyl ester, epoxy resin are being used for fiber reinforcement plastics (FRP) fabrication. Different grades of epoxy
resins and hardener combinations are classified, based on the mechanical properties. Among these grades, the grade of epoxy
resin selected is Dobeckot 520 F and the grade of hardener used for this application is 758. Dobeckot 520 F is a solvent less epoxy
resin. This in combination with harder 758 cures into hard resin. Hardener 758 is a low viscosity polyamine. Dobeckot 520 F and
Hardener 758 combination is characterized by good mechanical and electrical properties, faster curing at room temperature and
good chemical resistance properties.
D. MANUFACTURING OF COMPOSITE LEAF SPRING
Hand layup technique is suitable for manufacturing of composite leaf spring with suitable effective properties. In this
process a mould cavity made up with the help of wooden sheet and plaster of paris, optical gel coating of suitable thickness layer
is made in the boundary of cavity. resin in liquid form is poured in that cavity. To get required thickness alternate layers of resin
and dry reinforcement fabric are deposited and pressed with rollers.

Fig.2 Hand lay up Technique

E. MECHANICAL PROPERTIES OF MATERIAL [1]

Table 1: The mechanical properties of steel leaf spring
Properties
Value
Unit
Youngs modulus
200000
Mpa
Tensile strength
650-880
Mpa
Elongation
8-25
%
Fatigue
275-275
Mpa
Yield strength
350-550
Mpa
Density
7700
Kg/m3

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ISSN: 2395-0560

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Volume1, Issue 5 of May 2015

Table 2: The mechanical properties of E-glass/epoxy

Properties
Value
Tensile modulus along X-direction (Ex), MPa
34000
Tensile modulus along Y-direction (Ey), MPa
6530
Tensile modulus along Z-direction (Ez), MPa

6530

Tensile strength of the material, MPa

900

Compressive strength of the material, MPa

450

Shear modulus along XY-direction (Gxy), MPa

2433

Shear modulus along YZ-direction (Gyz), MPa

1698

Shear modulus along ZX-direction (Gzx), MPa

2433

Poisson ratio along XY-direction (NUxy)

0.217

Poisson ratio along YZ-direction (NUyz)

0.366

Poisson ratio along ZX-direction (NUzx)

0.217

Mass density of the material (), kg/mm3

2.6*106

Flexural modulus of the material, MPa

40000

Flexural strength of the material, MPa

1200

III. SPECIFICATIONS OF STEEL LEAF SPRING

Specifications of Leaf spring used in suspension light vehicle are shown in Table 3.

Length(L)

Table 3: Leaf spring Specification

915 mm

Width(b)

50 mm

Thickness (t)

6 mm

Chamber height

130 mm

The stress and deflection of spring under load are calculated.

IV. SOLID MODELING OF STEEL LEAF SPRING

Using Creo parametric software solid modeling of leaf spring is carried out.

Fig.3 Modeling of leaf spring by Creo parametric

V.

ANALYSIS USING ANSYS

The model of leaf spring is imported to ANSYS 14, the boundary conditions and material properties are specified form the
standards used in the practical applications. The structural steel having approximately similar isotropic behavior and properties as
compared to composite material is selected.

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Volume1, Issue 5 of May 2015
Model of parabolic spring was partitioned into small regions for easier meshing as shown in fig. 4. the boundary condition are set
according to static load acting on the front eye causing rotation about y axis, rear eye is constrained in y and z translation, x and
z rotations, allowing free x translation and y rotation. Vertical load is applied at the center of leaf spring. The FEA results for
steel leaf spring and mono composite leaf spring are shown in fig. 5 and 6 respectively and tabulated in table 4.

Fig.4 : Meshing of Model

Fig.5 : Stress analysis of steel material (FEA Analysis)

Fig.6 : stress analysis of composite material (FEA Analysis)

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ISSN: 2395-0560

International Research Journal of Innovative Engineering

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Volume1, Issue 5 of May 2015

Table 4. Analytical and FEA Analysis

parameters
Analytical
FEA
steel
Epoxy
steel
Epoxy
Load(N)
180
180
180
180
Stress
296.46 338.81
209
212.8
(N/mm2)
Deflection 1.65
18.38
4.07
20.13
(mm)
Weight(kg) 2.725
0.449

VI.

ADVANTAGES

Specially made to give effects like air suspension without any extra external energy.
No permanent deformation.
Softer ride, lower noise level.
Increase in fuel efficiency due to better aerodynamic.

VII. CONCLUSION
These work involves the comparison of conventional steel and Composite material leaf spring under static loading
conditions the model is developed using Creo parametric software and then analysis is performed through ANSYS 14.0 from the
result obtained it is concluded that the development of a composite mono leaf spring having constant cross sectional area, where
the stress level at any section in the leaf spring is considered constant due to the parabolic type of the thickness of the spring, has
proved to be very effective.

VIII. ACKNOWLEDGEMENTS
We are thankful to Prof. Nagendra I J, and Dr. K K Dhande Head of Department, for their valuable suggestions and guidance. I
am also thankful to M/s Raval Composite, Surat for providing facilities for fabrication of the model.

REFERENCES
[1] Gulur siddaramanna Shiva Shankar & Sambagam Vijayarangan (2006), Mono Composite Leaf Spring for Light Weight Vehicle- Design,

End Joint Analysis and Testing, Journal-ISSN 1392-1320, Material science Vol 12.No.3.
[2] V.Pozhilarasu, T. Parameshwaran Pillai, Comparison of Performance of Glass Fiber Reainforced Plastic Leaf Spring With Steel Leaf
spring. International Jouranal of ChemTech Research, CODEN(USA): IJCRGG ISS : 0974-4290 Vol.5, No.3, pp 1339-1345, April-June
2013.
[3] G.S.Shivashankar, S.Vijayarangan, D. Rajiv, R.Pradeep, Research Scholar and Corresponding Author. PSG College of
Technology.Coimbatore-641004,india.
[4] Pankaj Saini, Ashish Goel, Dushyant Kumar,DESIGN AND ANALYSIS OF COMPOSITE LEAF SPRING FOR LIGHT VEHICLE
International of Innovative Research in Science, Engineering and Technology. ISSN: 2319-8753, Vol 2, Issue, may 2013.
[5] D. K. Damor, K. D. Kothari, RK University, Rajkot, A Review on Design and Analysis of Long Fiber Reinforced Thermoplastic Leaf
Spring, ISSN-2250-1991, Vol. 2 Issue-3, March-2013.
[6] ASME Standard specification of design data handbook.

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