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ABSTRACT
In the present work, steel leaf spring used in passenger cars is replaced with a composite leaf spring made of a
glass/epoxy composite The primary objective is to compare fatigue characteristics of SAE1045-450-QT steel and E -
Glass/ Epoxy Composite material. Based on the available design data a fatigue analysis is carried out on an ANSYS
Workbench v14.0 and the results of the simulation are documented. Factors like fatigue life, fatigue damage, biaxiality
indication, rain flow counting and fatigue response are plotted for the composite leaf spring and the fatigue performance is
predicted using life data. Therefore the objective of this paper is to present a design and simulation study on the fatigue
performance of a glass fibre/epoxy composite leaf spring through design and finite element method and prove the
reliability of the validation methods based only on simulation, thereby saving time, material and production costs for a
complete product realization.
Keywords: glass fibre/epoxy composite, leaf spring, design for fatigue, finite element method, ANSYS workbench v14.0.
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VOL. 9, NO. 3, MARCH 2014 ISSN 1819-6608
ARPN Journal of Engineering and Applied Sciences
2006-2014 Asian Research Publishing Network (ARPN). All rights reserved.
www.arpnjournals.com
Element analysis (FEA) is carried out at static condition of Mechanical and Cyclic Properties of SAE1045-
the spring model so that stress distribution can be 450-QT and E - Glass/ Epoxy Composite material are
observed for analysis of high stress zones. The original listed in the Tables 2 and 3, respectively [11, 12]
steel leaf spring would weigh about 3.5 kgs whereas
composite leaf spring would weigh 0.7314 kgs. So, we Table-2. Mechanical and cyclic properties of SAE
have observed that almost 65-70% of weight reduction 1045-450- QT
could be achieved by using the carbon composite [7].
Whereas, Design and experimental analysis of composite Material properties Value
multi leaf spring using glass fibre reinforced polymer Elastic Modulus (E), GPa 207
compared to steel spring, found to have 67.35% lesser
stress, 64.95% higher stiffness and 126.98% higher natural Yield Tensile Strength , MPa 1515
frequency than that of existing steel leaf spring. The Ultimate Tensile Strength, MPa 1584
conventional multi leaf spring weighs about 13.5 kg Cyclic Strength Coefficient (K) 1874
whereas the E-glass/Epoxy multi leaf spring weighs only
4.3 kg. Thus the weight reduction of 68.15% is achieved. Fatigue Strength Coefficient (Sf) 1686
Besides the reduction of weight, the performance of the Fatigue Strength Exponent (b) -0.06
leaf spring is also increased. Ride comfort and life of
Composite Leaf Spring are also more when compared to Fatigue Ductility Exponent (c ) -0.83
Steel Leaf Spring [2]. Composite leaf spring is lighter than Fatigue Ductility Coefficient (Ef) 0.79
conventional steel leaf spring with similar design
Cyclic Strain Hardening Exponent (n) 0.09
specifications but not always is cost effective over their
3
steel counterparts. The life of the spring is an important Density , Kg/m 7.7 103
criterion. In this aspect as well composite leaf spring Possions ratio 0.266
proves to be much better than EN45 steel leaf spring. The
predicted life of the composite leaf spring is 109cycles as Behaviour Isotropic
compared to 106 cycles of steel leaf spring [8].
A four-leaf steel spring used in the rear Table-3. Mechanical and cyclic properties of E glass/
suspension system of light vehicles replaced with an epoxy composite material.
optimized composite one. Main consideration was given to
the optimization of the leaf spring geometry to give the Material properties Value
minimum weight. The results showed that the optimum Tensile modulus along X-direction (Ex), MPa 34000
spring width decreases hyperbolically and the thickness Tensile modulus along Y-direction (Ey), MPa 6530
increases linearly from spring eye towards the axle seat.
Tensile modulus along Z-direction (Ez), MPa 6530
The natural frequency of composite leaf spring is higher
than that of the steel leaf spring and is far enough from the Tensile strength of the material, MPa 900
road frequency to avoid the resonance [9]. Composite Compressive strength of the material, MPa 450
materials have high elastic strain energy storage capacity Shear modulus along XY-direction (Gxy),
and high strength to weight ratio Therefore, it is concluded 2433
MPa
that composite leaf spring is an effective replacement for Shear modulus along YZ-direction (Gyz),
the existing steel leaf spring in automobile [10]. 1698
MPa
Shear modulus along ZX-direction (Gzx),
SPECIFICATION AND MATERIAL PROPERTIES 2433
MPa
OF LEAF SPRING
Parameters of the steel leaf spring and Composite Poisson ratio along XY-direction (NUxy) 0.217
leaf spring are listed in Table-1. Poisson ratio along YZ-direction (NUyz) 0.366
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VOL. 9, NO. 3, MARCH 2014 ISSN 1819-6608
ARPN Journal of Engineering and Applied Sciences
2006-2014 Asian Research Publishing Network (ARPN). All rights reserved.
www.arpnjournals.com
ASSUMPTIONS
SAE1045-450-QT multi leaf and E-Glass Epoxy
composite mono leaf spring modelled with constant
thickness and constant width design.
Unidirectional (0) E-Glass Epoxy composite layup are
assumed along the longitudinal direction of spring.
The constraints parameter i.e. dimensions and boundary
condition of SAE1045-450-QT multi leaf spring is same
as that of E-Glass Epoxy composite leaf spring.
Fatigue life predication of leaf spring based on finite
element analysis using Stress life approach. Figure-3. Boundary condition - leaf spring.
D.O.F.
Front eye Rear eye
constrained
Translation X, Y and Z Y and Z
constrained direction direction
Rotation X and Z X and Z
constrained direction direction
Free X
Allowing Free Y rotation translation and Y
rotation
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VOL. 9, NO. 3, MARCH 2014 ISSN 1819-6608
ARPN Journal of Engineering and Applied Sciences
2006-2014 Asian Research Publishing Network (ARPN). All rights reserved.
www.arpnjournals.com
Firstly, produced stress-time ( - t) or strain-time glass-epoxy figure is for transverse loading condition is
( - t) history data point from the geometry and loading, considered.
then material fatigue properties are introduced to estimate
life. In case of may be small changes in structural
behaviour which is to be modelled as well as detailed
FEM modelling procedures such as meshing and with B.C.
& loading, have large effects on predicted stresses. So, it
is important to admire greatly the issue of accuracy with
FEM Models, while performing fatigue life calculations.
Finite Element based calculations should only be
undertaken when correlated against test. Engineers were
doing fatigue calculation must have knowledge of
dimension involved in various parts of behaviour. Also
should have appreciation of material fatigue curves. i.e., S-
N Curve.
An integrated Finite Element based fatigue
environment analysis is complete analysis of a full load
component. Fatigue technique based on generally Stress-
Life, Strain- Life or Crack-Propagation estimation Figure-6. S-N curves for E-Glass/epoxy composite.
methods. But it is important to recognize that, Absolute
fatigue life is unobtainable. The schematic diagram of the The S-N graph: SAE1045-450-QT steel material
integrated FE based fatigue life prediction analysis is as shown in Figure-7 [11].
shown in Figure-5 [11].
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VOL. 9, NO. 3, MARCH 2014 ISSN 1819-6608
ARPN Journal of Engineering and Applied Sciences
2006-2014 Asian Research Publishing Network (ARPN). All rights reserved.
www.arpnjournals.com
MODAL ANALYSIS FOR RIDE COMFORT the number of cycles upto leaf spring will fail due to
To avoid resonant condition, leaf spring has to be fatigue. When leaf spring subjected to high cycle fatigue,
designed with respect to road frequency in such way that, where stresses are mainly elastic, the fatigue total-life (S-
its natural frequency should be maintained to provide ride N) approach is used for the life prediction.
comfort to passenger. The road irregularities usually have Fatigue life can be calculated, number of cycle to
the maximum frequency of 12 Hz (Yu and Kim, 1988) [7]. failure, of mono composite leaf spring using equation (1).
Therefore more the natural frequency of leaf spring
required. In modal analysis only boundary conditions are
applied and no load is acted on the leaf spring.
(2)
FATIGUE LIFE
According to assumptions, if loading is of
constant amplitude in stress life analysis, this represents
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VOL. 9, NO. 3, MARCH 2014 ISSN 1819-6608
ARPN Journal of Engineering and Applied Sciences
2006-2014 Asian Research Publishing Network (ARPN). All rights reserved.
www.arpnjournals.com
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VOL. 9, NO. 3, MARCH 2014 ISSN 1819-6608
ARPN Journal of Engineering and Applied Sciences
2006-2014 Asian Research Publishing Network (ARPN). All rights reserved.
www.arpnjournals.com
CONCLUSIONS
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ARPN Journal of Engineering and Applied Sciences
2006-2014 Asian Research Publishing Network (ARPN). All rights reserved.
www.arpnjournals.com
[3] B. Raghu Kumar, R. Vijaya Prakash and N. Ramesh. Research (IJMER). ISSN: 2249-6645. 2(1): 213-218,
2013. Static analysis of mono leaf spring with January-February.
different composite materials. Journal of Mechanical
Engineering Research. ISSN: 2141-2383. 5(2): 32-37,
February.
[10] Sachin Kr. Patel, A.K. Jain and Pratik Gandhi. 2012.
Review of Effect of Material on Fatigue Life of Leaf
Spring. VSRD International Journal of Mechanical,
Civil, Automobile and Production Engineering. 2(4):
161-165.
203
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