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1.1 Introduction :
Leaf springs are composed of flat bars of varying lengths ( laminated form ) to obtain greater efficiency and resilience . A common trouble with laminated springs is fatigue failure of the leaves . Some factors contributing to this type of failure are the weakening effect of the hole if the center bolt is used ; contact pressure produced by U-bolts and rebound clips ; stress concentration caused by improperly shaped leaf ends ; initial curvature and relative change of curvature of the leaves during loading ; vibration of the spring ends during rebound , which may cause breakage of a leaf at an unloaded location ; and improper heat treatment , especially surface decarburization . Each of these factors has at least a partial cure , which should be incorporated in leaf spring design. Leaf springs are widely used in railway wagons , coach and road vehicles . They are loaded at the ends and supported in the middle . They are essentially the beams of uniform strength . when the full load is applied , the central deflection disappears , and the plate becomes flat . The leaves are held together by a bolt passing through the centre or by a shrunk band around them (1) . Also leaf springs may be full elliptic , semi elliptic and cantilever as shown in fig. (1.1)
In these type of springs the major stresses are tensile & compressive . (2)
:springs
Following are the standard sizes for automobile suspension springs :
1- Standard nominal widths are : 32,40*,45,50*,55,60*,65,70*,75,80,90,100 and 125 mm.( Dimension marked * are the preferred widths ) 2- Standard nominal thickness are : 3.2,4.5,5,6,5.6,7,7.5,8,9,10,11,12,14 and 16 mm. 3- At the eye , the following bore diameters are recommended : 19,20,22,23,25,27,28,30,32,35,38,50 and 55 mm . 4- Dimension for the centre bolts , if employed , shall be as given in the following table .
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5- Minimum clip sections and the corresponding sizes of rivets and bolts used with the clips shall be as given in the following table.(3)
2- For rail road springs : C 55 ( water hardened), c 75 (oilhardened),40 Si 2 Mn 90 ( water hardened), and 55 Si 2 Mn 90(oil-hardened) . 3- The physical properties of some of these materials are given in the following table. All values are for oil quenched condition and for single heat only .
Table 1.3. physical properties of materials commonly used for leaf springs.
Material Condition Ultimate tensile strength(Mpa) Tensile yield strength (Mpa) 1540-1750 1680-1890 1680-1920 Brinell hardness number 461-601 534-601 534-601
50 Cr 1 50 Cr 1 v 23 55 Si 2 Mn 90
1.4 Characteristics :
1- The leaf spring acts as a linkage for holding the axle in position and thus separate linkage are not necessary. It makes the construction of the suspension simple and strong.(4) 2- As the positioning of the axle is carried out by the leaf springs so it makes it disadvantageous to use soft springs i.e. a spring with low spring constant. 3- Therefore, this type of suspension does not provide good riding comfort. The inter-leaf friction between the leaf springs affects the riding comfort. 4- Acceleration and braking torque cause wind-up and vibration. Also wind-up causes rear-end squat and nose-diving.
1. Eye reaming / eye boring 2. Bush insertion 3. Bush reaming 7. Assemble : 1. Presetting & load testing 2. Paint touch-up 3. Marking & packing
1.6 Advantages :
The advantage of leaf spring over helical spring is that the ends of the spring may be guided along a definite path as it deflects to act as a structural member in addition to energy absorbing device . Thus the leaf springs may carry lateral loads , brake torque , driving torque etc., in addition to shocks .(4)
Fig.1.6.leaf spring
T= Where : w : Load of pin L : Effective length of the spring : Maximum of leaves b : width of leaves ng : Number of graduated leaves nf :Number of full length leaves
(2.1)
2.2.Deflection of spring
The equation used to calculate deflection of spring is : = Where : E: young modulus (2.2)
The equation used to calculate diameter of eye is : To calculate inner dia. d= l1pb / w To calculate outer dia. D= Where : L1 :length of the pin which is equal to the width of the eye or leaf Pb :bearing pressure on the pin b:bending stress M : maximum bending moment of the pin Z : section modulus (2.4) (2.3)
The equation used to calculate length of leaves is : Length of the smallest leaf = + ineffective length Length of the 2nd leaf = (2.5)
+ ineffective length
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(2.6)
Length of the 3rd leaf = + ineffective length Length of the 4th leaf = + ineffective length Length of the 5th leaf = + ineffective length Length of the 6th leaf = (2.9) (2.8) (2.7)
+ ineffective length
(2.10)
The 6th and 7th leaves are full length leaves and the 7th leaf ( i.e the top leaf ) will act a master leaf . Length of the master leaf = 2L1+
(2.11)
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References : 1- Paul H. Black K , Machine design ,McGra W-Hill book company . O.Eugene adams GR. , Machine design ,McGra W-Hill book company . 2- R.B. Guta , Mechanical Engineering Design , Shri R.P. Handa prop Satya Prakashan , First addition , July 1947. 3- Guta , A Textbook of Machine Design . 4- Www.google.com
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