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We know that the maximum deflection for a cantilever with concentrated load at the free end is
given by
It may be noted that due to bending moment, top fibres will be in tension and the bottom fibres
are in compression, but the shear stress is zero at the extreme fibres and maximum at
the centre, as shown in Fig. Hence for analysis, both stresses need not to be taken into
account simultaneously.
We shall consider the bending stress only.
the centre, as If the spring is not of cantilever type but it is like a simply supported beam,
with length 2L and load 2W in shown in Fig., then Maximum bending moment in the centre,as
shown in fig, then
Maximum bending moment in the center,
M=W.L
A little consideration will show that by the above arrangement, the spring becomes compact so
that the space occupied by the spring is considerably reduced. When bending stress alone is
considered, the graduated leaves may have zero width at the loaded end. But sufficient metal
must be provided to support the shear. Therefore, it becomes necessary to have one or more
leaves of uniform cross-section extending clear to the end. We see from equations (iv) and (vi)
that for the same deflection, the stress in the uniform cross-section leaves (i.e. full length
leaves) is 50% greater than in the graduated leaves, assuming that each spring element
deflects according to its own elastic curve. If the suffixes F and G are used to indicate the
full length (or uniform cross section) and graduated leaves, then
Raw material
Generally leaf springs are made of various fine grade alloy steel. The most
commonly used grades of steel are 55 Si 7,60 Si Cr7,50 Cr V4. The others are En 45 A, 65 Si
7,55 Si Cr 7,65 Si cr7,En 42 60 s 87.
In our project we are going to use En 42 60 S87 grade of steel
alloy.Generally the width of the raw material varies from 40-100 mm and thickness varies from
4
to 20mm.
Furnace oil and the air are used for heating the furnace. The furnace is first allowed to heat
freely for 45 mins. Now the master blades are placed in the furnace such that only ends are
heated.
After heating is done for one end it is bend to form the eye and again it is
placed in the furnace to heat the other end. After heating the main blade is bent slightly to form
curve at the end with the help of 50 ton punching machine so that it will be easy to roll to form
eye formation.
In the eye rolling machine the master blade end is placed between the circular wheel and the
die. after placing the hand lever is moved so that the end of the master blade rolls over the die
thus forming eye shape
Hardening (Quenching)
Hardening is carried out to achieve the maximum hardness.
The main blades after the eye formation are heated to a temperature of 800-1000
degree centigrade in a furnace to increase the hardness of the material.
The other blades along with main blades are heated in the furnace. The furnace is heated by
using air and furnace oil through conventional air flow system. The conventional air flow
system is used to mix both air and furnace oil for heating purpose. A pump is provided
for the air to go out.
After heating the blades in the furnace for 45 minutes they are taken out and bent to
the required angle on the hydraulic bending machine. The required angle can be obtained by
using required angle dies.
The blades after making the required angle they are immersed in the Quenchngon oil to
increase the hardness. The hardness at the end of this stage is about 50 to 60.
Tempering
Quenched steel, while very hard and strong, is too brittle to be useful for most
applications. A method for alleviating this problem is called tempering. For most steels,
tempering involves heating to between 250 and 500 C, holding that temperature (soaking)
for an appropriate amount of time (on the order of seconds or hours), then cooling
slowly over an appropriate length of time (minutes or hours). This heat treatment results in
higher toughness and ductility, without sacrificing all of the hardness and tensile strength
gained from rapid quenching. Tempering balances the amount of hard martensite with ductile
ferrite and pearlite.
In some applications, different areas of a single object are given different heat
treatments.
This is called differential hardening. It is common in high quality knives and swords.
Clamps
Clamps are the devices which are used for holding the leaf springs together. Clamps are made
of Mild Steel.
Procedure for making clamps
At first the material is cut into the required length on the 50 ton cutting machine by
using blades. Next the cutted material is punched on the 5o ton punching machine to obtain