Design Analysis, Fabrication And Testing Of composite Leaf Spring

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CHAPTER 1
INTRODUCTION
In order to conserve nat ral reso rces and economi!e energy, "eig#t red ction #as been t#e main foc s of a tomobile man fact rers in t#e present scenario$ %eig#t red ction can be ac#ieved primarily by t#e introd ction of better material, design optimi!ation and better man fact ring processes$ T#e s spension leaf spring is one of t#e potential items for "eig#t red ction in a tomobiles as it acco nts for &'( ) *'( of t#e nspr ng "eig#t$ T#is ac#ieves t#e ve#icle "it# more f el efficiency and improved riding + alities$ T#e introd ction of composite materials "as made it possible to red ce t#e "eig#t of leaf spring "it#o t any red ction on load carrying capacity and stiffness$ Since, t#e composite materials #ave more elastic strain energy storage capacity and #ig# strengt# to "eig#t ratio as compared "it# t#ose of steel, m lti)leaf steel springs are being replaced by mono)leaf composite springs$ T#e composite material offer opport nities for s bstantial "eig#t saving b t not al"ays be cost)effective over t#eir steel co nterparts$ T#e s b,ect gives a brief loo- on t#e s itability of composite leaf spring on ve#icles and t#eir advantages$ Efforts #ave been made to red ce t#e cost of composite leaf spring to t#at of steel leaf spring$ T#e ac#ievement of "eig#t red ction "it# ade+ ate improvement of mec#anical properties #as made composite a very replacement material for convectional steel$ .aterial and man fact ring process are selected pon on t#e cost and strengt# factor$ T#e design met#od is selected on t#e basis of mass prod ction$ From t#e comparative st dy, it is seen t#at t#e composite leaf spring are #ig#er and more economical t#an convectional leaf spring$ 1.1.Background and scope Leaf springs #ave been sed in many passenger cars and tr c-s for a long time$ T#e be#avior of t#is -ind of springs is nonlinear$ /elatively #ig# "eig#t, self)steering and c#ange in solid a0le angle d e to "eig#t transfer specially in cornering t#at "ill lead to over steer and directional instability are some defects of leaf springs$ Considering a tomotive development and importance of relative aspects s c# as1 f el cons mption ,poll tion, "eig#t, ride and #andling, development of ne" materials is necessary in t#is ind stry$ Composites d e to t#eir #ig# level of strengt# to "eig#t ratio, are more s itable among ot#er materials$ /eplacement of e0isting fo r) layer steel leafspring in 2E34EOT /D "it# one)layer composite one is an e0ample of t#ese efforts$ T#e first composite leaf spring in Iran "as designed and prod ced by Iran Composite Association for 2E34EOT /D$ T#e spring #ad one layer of epo0y resin and glass fibers t#at "ere

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Design Analysis, Fabrication And Testing Of composite Leaf Spring laid in longit dinal direction$ 1.2 Objec !"e &5 *5 65

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T#e main ob,ective is to decrease t#e "eig#t of leaf spring$ To ma-e a comparison bet"een ordinary steel leaf spring and a composite leaf spring$ To eval ate t#e applicability of a composite leaf spring in a tomobiles by considering cost) effectiveness and strengt#$

1.# $e %odo&og' &5 Information abo t composite materials "ere collected from internet and ,o rnals$ *5 65 7 merical data8s and e0perimental res lts for t#e comparison bet"een composite leaf spring and conventional leaf spring "as obtained from ,o rnals$ T#e information8s and datas from different ,o nals "ere sorted to ma-e t#is paper$

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Design Analysis, Fabrication And Testing Of composite Leaf Spring

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CHAPTER 2 (ITERATURE RE)IE*

Investigation of composite leaf spring in t#e early 9':s failed to yield t#e prod ction facility beca se of inconsistent fatig e performance and absence of strong need for mass red ction$ /esearc#es in t#e area of a tomobile components #ave been receiving considerable attention no"$ 2artic larly t#e a tomobile man fact rers and parts ma-ers #ave been attempting to red ce t#e "eig#t of t#e ve#icles in recent years$ Emp#asis of ve#icles "eig#t red ction in &;<= , stified ta-ing a ne" loo- at composite springs$ St dies are made to demonstrate viability and potential of F/2 in a tomotive str ct ral application$ T#e development of a lite fle0 s spension leaf spring is first ac#ieved$ >ased on consideration of c#ipping resistance base part resistance and fatig e resistance, a carbon glass fiber #ybrid laminated spring is constr cted$ A general disc ssion on analysis and design of constant "idt#, variable t#ic-ness, composite leaf spring is presented$ T#e f ndamental c#aracteristics of t#e do ble tapered F/2 beam are eval ated for leaf spring application$ /ecent developments #ave been ac#ieved in t#e field of materials improvement and + ality ass red for composite leaf springs based on microstr ct re mec#anism$ All t#ese literat re report t#at t#e cost of composite1 leaf spring is #ig#er t#an t#at of steel leaf spring$ ?ence an attempt #as been made to fabricate t#e composite leaf spring "it# t#e same cost as t#at of steel leaf spring$ $ .aterial properties and design of composite str ct res are reported in many literat res$ @ery little information are available in connection "it# finite element analysis of leaf spring in t#e literat re, t#an too in *D analysis of leaf spring$ At t#e same time, t#e literat re available regarding e0perimental stress analysis more$ T#e e0perimental proced res are described in national and international standards$ /ecent emp#asis on mass red ction and developments in materials synt#esis and processing tec#nology #as led to proven prod ction "ort#y ve#icle e+ ipment$

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Design Analysis, Fabrication And Testing Of composite Leaf Spring

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CHAPTER #
$ATERIA(+ +E(ECTION
.aterials constit te nearly 9'()<'( of t#e ve#icle cost and contrib te to t#e + ality and t#e performance of t#e ve#icle$ Even a small amo nt in "eig#t red ction of t#e ve#icle, may #ave a "ider economic impact$ Composite materials are proved as s itable s bstit tes for steel in connection "it# "eig#t red ction of t#e ve#icle$ ?ence, t#e composite material #ave been selected for leaf spring design$

#.1.,!ber se&ec !on T#e commonly sed fibers are carbon, glass, -evlar, etc$$ Among t#ese, t#e glass fiber #as been selected based on t#e cost factor and strengt#$ T#e types of glass fibers are C) glass,S)glass and E)glass$ T#e C)glass fiber is designed to give improved s rface finis#$ S)glass fiber is design to give very #ig# mod lar, "#ic# is sed partic larly in aerona tic ind stries$ T#e E)glass fiber is a #ig# + ality glass, "#ic# is sed as standard reinforcement fiber for all t#e present systems "ell complying "it# mec#anical property re+ irements$ T# s, E)glass fiber "as fo nd appropriate for t#is application$ #.2.Res!n se&ec !on In a F/2 leaf spring, t#e inter laminar s#ear strengt#s is controlled by t#e matri0 system sed $since t#ese are reinforcement fibers in t#e t#ic-ness direction , fiber do not infl ence inter laminar s#ear strengt#$ T#erefore, t#e matri0 system s#o ld #ave good inter laminar s#ear strengt# c#aracteristics compatibility to t#e selected reinforcement fiber$ .any t#ermo set resins s c# as polyester, vinyl ester, a!po0y resin are being sed for fiber reinforcement plastics AF/2B fabrication $ Among t#ese resin systems, epo0ies s#o" better inter laminar s#ear strengt# and good mec#anical properties$ ?ence, epo0ide is fo nd to be t#e best resins t#at "o ld s it t#is application$ Different grades of epo0y resins and #ardener combinations are classifieds , based on t#e mec#anical properties$ Among t#ese grades , t#e grade of epo0y resin selected is Dobec-ot C*' F and t#e grade of #ardener sed for t#is application is <C=$Dobec-ot C*' F is a solvent less epo0y resin,

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%#ic# in combination "it# #ardener <C= c res into #ard resin$ ?ardener <C= is a lo" viscosity polyamine $ Dobec-otC*'F, #ardener<C= combination is c#aracteri!ed by , &B 4ood mec#anical and electrical properties$ *B$Faster c ring at room temperat re$ 6B$4ood c#emical resistance properties$ #.#.Proper !es o- E.g&ass / Epo0' co1pos! e >y considering t#e property variation in t#e tapered system improper bonding and improper c ring, etc$ some constant of property val e are red ced from calc lated val es sing e+ ations$ T#e material properties for E)glass D Epo0y composite for 9'( of fiber vol me is given belo"E) #.#.1.Proper !es "a&ues +'1b o& E0 Ey E!

Proper ' Tensile .od l s along F direction Tensile .od l s along G direction Tensile .od l s along H direction Tensile strengt# of t#e material Compressive strengt# of t#e material S#ear mod l s along FG direction S#ear mod l s along GH direction S#ear mod l s along HF direction Fle0 ral mod l s of t#e material Fle0 ral strengt# of t#e material 2oisson ratio along FG direction 2oisson ratio along GH direction 2oisson fatio along HF direction

"a&ue 12333 43#3 15#3 633 253 22## 1433 22## 23333 1333

40y 4y! 4!0

730y 73y! 73!0

.217 .#44 .217

Table 6$&$2/O2E/TG @AL3ES OF E)4LASSDE)2OFG

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Design Analysis, Fabrication And Testing Of composite Leaf Spring

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CHAPTER 2
DE+I8N +E(ECTION
T#e leaf spring be#aves li-e a simply s pported beam and t#e fle0 ral analysis is done considering it as a simply s pported beam$ T#e simply s pported beam is s b,ected to bot# bending stress and transverse s#ear stress$ Fle0 ral rigidity is an important parameter in t#e leaf spring design and test o t to increase from t"o ends to t#e center$ 2.1.Cons an %!ckness9 "ar'!ng :!d % des!gn In t#is design t#e t#ic-ness is -ept constant over t#e entire lengt# of t#e leaf spring "#ile t#e "idt# varies from a minim m at t#e t"o ends to a ma0im m at t#e center$ 2.2.Cons an :!d %9 "ar'!ng %!ckness des!gn In t#is design t#e "idt# is -ept constant over t#e entire lengt# of t#e leaf spring "#ile t#e t#ic-ness varies from a minim m at t#e t"o ends to a ma0im m at t#e center$ 2.#.Cons an cross.se&ec !on des!gn In t#is design bot# t#ic-ness and "idt# are varied t#ro g# o t t#e leaf spring s c# t#at t#e cross)section area remains constant along t#e lengt# of t#e leaf spring$O t of t#e above mentioned design concepts, t#e constant cross)section design met#od is selected d e to t#e follo"ing reasonsE) &BD e to its capability for mass prod ction and accommodation of contin o s reinforcement of fibers$ 2;Since t#e cross)section area is constant t#ro g# o t t#e leaf spring, same + antity of reinforcement fibre and resin can be fed contin o sly d ring man fact re$ #; Also t#is is + ite s itable for filament "inding process$

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Design Analysis, Fabrication And Testing Of composite Leaf Spring

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CHAPTER 5
+E(ECTION O, $ANU,ACTURIN8 PROCE++
Apart from t#e selection of material and design proced re, t#e selection of man fact ring process also determines t#e + ality and cost of t#e prod ct$ ?ence, t#e composite leaf spring man fact ring process s#o ld f lfill t#e follo"ing criteria$ IT#e process s#o ld be amenable to mass prod ction I T#e process s#o ld be capable of prod cing contin o s reinforcement fiber >ased on above re+ irements, filament)"inding tec#ni+ es is selected$ In filament "inding process, contin o s fibre nder controlled tension are dra"n from spools mo nted on creel stands "etted "it# t#e resin by passing t#e fibers t#ro g# a resin bat# and "o nd onto t#e rotating mo ld$ After ac#ieving t#e desired t#ic-ness, t#e process is stopped and t#e mo ld is removed from t#e mac#ine and -ept for c ring$ T#is process doesn8t involve # ge investment$

Fig C$&$FILA.E7T %I7DI74 2/OCESS

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Design Analysis, Fabrication And Testing Of composite Leaf Spring

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CHAPTER 4
,ABRICATION O, CO$PO+ITE (EA, +PRIN8
In t#is section t#e details of mo ld fabrication, filement "inding mac#ine, "inding set p, resin preparation, "inding process and metallic eye are disc ssed $ 4.1$ou&d -abr!ca !on T#e mo ld sed for t#e fabrication of F/2 leaf spring s#o ld satisfy t#e follo"ing re+ irements$ &I *I &I T#e cavity of t#e mo ld s#o ld resemble t#e act al leaf spring s#ape and dimension It s#o ld #ave a contin o s positive s rface of resol tion It s#o ld be designed s c# t#at it can be rotated abo t an a0is of revol tion

T#e mo ld is designed as per t#e design of t#e constant cross)section leaf spring and above t#e re+ irements$ After deciding t#e dimensions of t#e mo ld, it is man fact red sing "ood as t#e pattern material$ Adding small "ooden pieces along its bo ndaries create t#e composite leaf spring$ 4.2.,!&e1en :!nd!ng 1ac%!ne T#e mo ld t#at is sed for t#e man fact re of composite leaf spring #as an o ter dia$ of one meter$ T#e mo ld after mo nting on t#e mac#ine #as to be rotated as t#e fibre is "o nd on it$ ?ence a mac#ine, "#ic# #as t#e s"ing over dia$ of one meter #as to be sed T#is led to t#e selection of t#e #ori!ontal)boring mac#ine "#ic# #as an ad, stable s"ing over die$ An attac#ment is also fabricated for mo nting mo ld on to t#e spindle #ead of t#e boring mac#ine$ 4.#.*!nd!ng se up T#e act al "inding of t#e leaf spring involves t#e operation of t#e "inding mac#ine, after attac#ing t#e resin bat# and mo ld$ >efore t#e process is started, t#e epo0y resin and #ardener combination #as to be placed in t#e resin bat#$ T#e resin bat# is an important nit of t#e

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Design Analysis, Fabrication And Testing Of composite Leaf Spring

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"inding set p$ It provides t#e necessary matri0 impregnation to fibres before t#ey are "o nd over t#e mo ld s rface$ T#e resin bat# s#o ld accomplis# t#e follo"ing re+ irements$ &$ It s#o ld "et t#e fibre roving niformly "it# a controlled amo nt of resin$ *$ T#e capacity of t#e resin bat# s#o ld be s re t#at all t#e resin po red s#o ld be tili!ed completely 6$ T#e resin m st be po red at constant temperat re to maintain a constant viscosity$ J$ It s#o ld avoid fibre brea-age d ring impregnation$ T#e resin bat# consists of a n mber of rollers, "#ic# are placed to g ide t#e fibres$ T#e fibres from t#e creel stand are allo"ed to pass t#ro g# t#e rollers t#at are placed "ell inside t#e resin bat#$ T#is enables t#e fibres to get completely soa-ed in t#e resin$ T#e soa-ed fibre is t#en allo"ed to pass t#ro g# t"o rollers, "#ic# are rotating in pKopposite directions$ >y t#is met#od t#e amo nt of resin in t#e fiber is fo nd$ T#e filament "inding set p is s#o"n #ere$ T#e mo ld is first mo nted on t#e filament "inding sing t#e fabricated attac#ment and t#en it is rotated at a speed of &C rpm$ 4.2.Res!n prepara !on T#e selected epo0y resin is Dobec-ot C*' F "it# #ardener <C=$For every &'' parts by "eig#t of Dobec-ot C*' F ,&')&* parts by "eig#t of #ardener <C= is mi0ed "ell at a temperat re of *'LC) J'LC and sed "it#in 6')J' min, since t#e gel time of epo0y resin is 6')J' min$ 4.5.*!nd!ng process After t#e preparation of t#e resin, t#e resin is po red into t#e resin bat# and t#e fiber placed in t#e creel stand is allo"ed to pass t#ro g# rollers in t#e resin bat#$ T#e soa-ed fibre is t#en allo"ed to pass over t#e mo ld$ T#e process is contin ed till t#e desired t#ic-ness is ac#ieved 4.4.$e a&!c E'e Since it is diffic lt to fabricate a leaf spring "it# t#e eye portion by filament "inding process, a separate metallic eye is fabricated and t#en fi0ed to t#e leaf spring$

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Design Analysis, Fabrication And Testing Of composite Leaf Spring

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CHAPTER 7
TE+TIN8 O, CO$PO+ITE (EA, +PRIN8
In t#is section t#e mac#ine details and testing details of composite leaf spring are disc ssed$ T#e static and fatig e tests are also covered$ 7.1.Tes !ng 1ac%!ne T#e main problem faced in sing a standard material testing mac#ine for testing a leaf spring is t#e displacement$ T#e standard mac#ines are designed for a displacement in t#e order of microns$ > t t#e leaf spring testing mac#ine m st permit displacements in t#e order of centimeters$ T#e mac#ine m st be capable of e0erting #eavy loads in t#e range of a fe" tones$ T#e mac#ine m st be e+ ipped "it# a s itable fi0t re, "#ic# "ill sim late t#e act al mo nting of t#e leaf spring in t#e a tomobile$ T#is lead to t#e need of a servo)#ydra lic testing mac#ine for t#e testing of leaf springs$ ?ence, a #ydra lic)testing mac#ine for testing of leaf springs #as been designed and fabricate$ T#e special fi0t re arrangement for leaf spring testing is s#o"n bello"$ 7.2.Co1pos! e &ea- spr!ng es !ng T#e leaf springs are tested follo"ing standard proced res recommended by SAE$ T#e spring to be tested is e0amined for any defects li-e crac-s, s rface abnormality, etc$$ and t#e s rface "#ere t#e strain ga ges are to be fi0ed is cleaned free from d st, r st and any greases$ T#en, strain ga ges are fi0ed to t#e prepared s rface by sing a cyano)acrylate ad#esive$ 7.2.1.+ a !c es T#e composite leaf spring are tested sing leaf spring test rig $T#e e0perimental set p is s#o"n in fig AaB$T#e leaf spring are tested follo"ing standard proced res recommended by SAE$ T#e spring is loaded from !ero to ma0im m Deflection and bac- to !ero$ T#e load is applied at t#e center of t#e spring$ @ertical deflection of t#e spring center is also recorded

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Design Analysis, Fabrication And Testing Of composite Leaf Spring

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FigA&BELEAF S2/I74 TEST /I4

7.2.2,a !gue es A fatig e analysis is carried o t "it# t#e #elp of #ydra lic)fatig e testing mac#ine$ T#e designed and fabricated composite leaf spring is mo nted on testing mac#ine and t#e limit s"itc#es are fi0ed at a span of C' mm in t#e vertical direction$ T#is is t#e amplit de of loading cycle, "#ic# is considerably #ig# amplit de$ T#e fre+ ency of one cycle is 99 .?!, "#ic# is considered to be very lo"$ T#is leads to #ig# amplit de lo" fre+ ency fatig e test$ D ring t#e test t#e val e of strain at location & is recorded$ T#e ma0im m and minim m stress val es obtained at t#e first cycle of t#e composite leaf spring are *;; .2aand *'* .2a respectively$ As t#e n mber of cycles goes on increasing, t#e fl ct ation in t#e stress are contin ing to a certain level t#en settling ta-es place$ 3nder t#is condition, t#e ma0im m and minim m operating stress val es are fo nd to be 6&' .2a and *'= .2a, respectively$ Since, t#e fatig e AtensileB strengt# of t#e composite material is considered as ;'' .2a, t#e stress level obtained from operating stress is '$66, "#ic# is very lo" and safe$ D e to #ig# amplit de and lo" fre+ ency fatig e analysis, t#e e0perimental analysis does8nt provide final res lts in t#e s#ort period$ T#e test is cond cted for &'' to complete *C,''' cycles$ T#e variations in stress level are red ced to very lo" level after *C,''' cycles$ It is observed from t#e fatig e test t#at t#ere is only

a negligible red ction in spring rate A&$C(B and no crac- initiation in t#e spring after *C,''' cycles of fatig e loading$ ?ence t#ere is necessity to go for analytical model for finding t#e remaining n mber of cycles of fatig e$

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CHAPTER 6
RE+U(T+ AND DI+CU++ION+
T#e ob,ective of t#is st dy is to eval ate t#e applicability of a composite leaf spring in a tomobiles by considering cost)effectiveness and strengt#$ T#e comparison bet"een m lti)leaf spring and mono)leaf composite spring is made for t#e same re+ irements and loading conditions$ T#e comparison is based on fo r ma,or aspects s c# as "eig#t, riding comfort, cost and strengt#$ 6.1.Co1par!son o- :e!g% T#e total "eig#t of composite leaf spring is J Mg incl ding t#e metal eye "eig#t of & Mg$ T#e "eig#t of a convectional steel spring assembly is aro nd &C Mg$ So, aro nd <'( of "eig#t red ction is ac#ieved$ T# s t#e ob,ective of red cing t#e nspr ng mass is ac#ieved to a larger e0tent $ 6.2.Co1par!s!on based on r!g!d! ' <ua&! !es

T#e "eig#t red ction of nspr ng mass of an a tomobile "ill improve t#e riding + ality$ T#e s spension leaf contrib tes &'( ) *'( of t#e nspr ng mass$ T#e "eig#t of t#e composite leaf spring is 6$<C times less t#an steel leaf spring$ ?ence t#e riding comfort of an a tomobile is increased d e to t#e replacement of t#e steel leaf spring by composite leaf spring$ 7o one to t#e best of -no"ledge #as "or-ed b t + alitatively on #o" m c# improvement in mileageDlit of passenger ve#icle occ rs and #o" m c# riding comfort improves$ Only + alitative information is available on riding comfort of ve#icle "it# respect to its nspr ng mass$ Steel spring is a m lti)leaf spring and its inter)leaf fabrication red ces its riding + ality$ > t composite leaf spring is a mono)leaf spring and more cond ctive to riding + alities $ 6.#$Cos co1par!son

T#e cost estimation of composite leaf spring provides a clear economic viability of t#e prod ct in comparison to t#at of a convectional leaf spring$

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6.#.1.$ou&d cos

Cost inc rred in t#e man fact re of a mo ld is /s &J''$ T#is mo ld can be sed at least for C',''' cycles of man fact ring composite leaf springs t#ro g# filament "inding process and t#is res lts to man fact re of aro nd &,'',''' leaf spring$ ?ence, t#e cost distrib tion over &,'',''' leaf spring gives cost aro nd /s '$&J per leaf spring$.ac#ine ?o r /ate Of Filament %inding .ac#ine .ac#ine #o r rate of filament "inding mac#ine is aro nd /s &J' and time re+ ired in t#e man fact ring of t"o leaf spring is only 6' min$ t#erefore t#e cost involved is /s 6C$ 6.#.2.(abour and 1!sce&&aneous cos

T#e cost involved in employing s-illed labo r #as to be incorporated in t#e total cost$ In t#is case t#ere is no labo r involvement$ It is ass med t#at t#e labo r cost and miscellant cost in man fact re of t"o leaf spring is /s 6C 6.#.#.Cos o- con"ec !ona& &ea-

T#e convectional leaf spring assembly is available in t#e mar-et for /s &'''$ >y ass ming a profit margin of *C( of t#e leaf spring, t#e cost of t#e leaf spring "or-s o t to be /s <C'$ ?ence it concerns t#at t#e cost of a composite leaf spring is e+ al to t#at of a convectional leaf spring even at a development stage$ T#is s#o"s t#at if mass prod ction is ac#ieved t#e cost can be red ced by *'( ) 6'( of t#e cost of a convectional leaf spring$ 6.2.+ reng % co1par!son Static test #as been cond cted on steel and composite leaf spring$ T#e c#aracteristics of t#ese t"o are given belo"$
PARAMETER STEEL COMPOSITE

.a0im m Stress, .2a Safety Factor

Spring Rate N/mm

<JC &$6 to *$'

25 to 28

6'' 6$' to J$'

25 to 28

Table =$& C?A/CTE/STIC CO.2A/ISO7 >ET%EE7 STEEL A7D CO.2OSITE

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Since, t#e composite leaf spring is able to "it# stand t#e static load as "ell as t#e fatig e load, it is concl ded t#at t#ere is no ob,ection from strengt# point of vie" also, in t#e process of replacing convectional leaf spring by composite leaf spring$ To establis# t#e consistency of test res lts, e0tensive trail on a large scale #as to carried o t$ T#is re+ ires large time and infrastr ct re, "#ic# are beyond t#e scope of t#e present st dy$ Since, t#e composite spring is designed for same stiffness as t#at of steel spring, bot# t#e springs are considered to be almost e+ al in car stability$ T#e ma,or disadvantage of composite leaf springs is cost and resistance$ In t#is st dy, t#e cost factor #as been proved to be ineffective$ ?o"ever t#e matri0 material is li-ely to c#ip off "#en it is s b,ected to poor road environment Aie1 if some stone #it t#e composite leaf spring t#en it may prod ce c#ippingB, "#ic# may sometimes brea- t#e fibres in t#e lo"er portion of t#e spring$ T#is may res lt in a loss of capability to s#are fle0 ral stiffness$ > t t#is depends on t#e condition of t#e road$ In normal road condition, t#is type of problems "ill not occ r$ Fig * gives t#e comparison bet"een load Ndeflection c rves$ Fig 6 gives t#e comparison bet"een t#e variation of e0perimental stress "it# spring lengt#$ Fig 6 gives t#e comparison of variation of longit dinal stress "it# spring lengt#$

Fig.8.1.LOAD DEFLECTION C!R"E

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FI#.8.2 "ARIATION OF E$PERIMENTAL STRESS %IT& SPRIN# LEN#T&

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CHAPTER =
CONC(U+ION
&5 Design and man fact ring process of a composite leaf spring #as been disc ssed t#at is its design selection ,resin selection and its man fact ring process$ *5 Its fo nd t#at "eig#t red ction of aro nd <'( is obtained$ie an ordinary steel leaf spring "eig#s aro nd &C -g "#ereas a composite leaf spring "eig#s only J-g$ 65 Introd ction of composite leaf spring in a tomobiles "ill increase t#e riding + ality$ since composite leaf springs are mono leaf springs it "ill increase it #as got #ig# rigidity$ J5 T#e ma,or disadvantage of composite leaf spring is cost, b t it can be red ced by mass prod ction$ C5 Composite leaf spring is a good replacement for conventional steel leaf spring$

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RE,ERENCE+

&5 +%!"a +%ankar9"!ja'aranganOmono composite leaf spring for light weight vehichledesign,end joint analysis andvtesting:ISS7 &6;*)&6*' material science vol &* no 6 *''9 *5 +en %!&ku1ar and )!ja'arangan9Oanalytical and experimental studies on fatigue life prediction of steel and composite multi leaf spring for light passenger vehicles using life data analysis:ISS7&6;*)&6*' material science vol &6 no * *''< 65 > > ?ADHAO and Dr R.+.DA(U Oexperimental investigation and numerical analysis of composite leaf spring: international ,o rnal of engineering science and tec#nology J5 $ sen %!&ku1ar and + )!ja'arangan Ostatic analysis and fatigue life prediction of steel and composite leaf spring for light passenger vehichles: ,o rnal of science and ind strial researc# vol 99 ,*''<,pp &*=)&6J

B%us%an B Des%1uk% 9Dr+an os% B jaju ODesign and analysis of fibre reinforce polymer leaf spring a review: international ,o rnal of engineering science and tec#nology vol *AJB*'&&$, *=;)*;&

? P %ou9?.@C%erruau& 9 8 ?eron!1!d!s and R 1a'er Odesign testing and simulation of fibre composite leaf springs for heavy axle loads: ,o rnal on strain analysis vol J' no 9,I.ec#E *''C

$ $Pa unakar9D R Do&as AModelling and Analysis of composite Leaf spring under the static Load condition by using !A: International Jo rnal of .ec#anical and Ind strial Enginering , vol me & Iss e &)*'&&

Department Of Mechanical Engineering Page 17

Design Analysis, Fabrication And Testing Of composite Leaf Spring

AJCE

Department Of Mechanical Engineering Page 18

Design Analysis, Fabrication And Testing Of composite Leaf Spring

AJCE

Department Of Mechanical Engineering Page 19