FINITE ELEMENT ANALYSIS ON PARABOLIC LEAF SPRING IN SUSPENSION

SYSTEM
The objective of this study is to analyze and evaluate the capability of parabolic spring
Finite element analysis had been performed to analyze the stress distribution and behavior both type of springs.
Then, time histories service loading data was analyze and damage area was simulated to predict the fatigue life of
the components.
Using finite element analysis, high stress patent and deflection behavior of both springs can
be studied. Also, this FE model will be used in fatigue analysis in next step of study.

The large vehicles need a good suspension system that can be deliver a good ride and handling.
At the same time, that component need to be lightweight and had an excellent of fatigue life.
Fatigue is one of the major issues in automotive component. It must withstand numerous
numbers of cycles before it can fail, or never fail at all during the service period.
From the viewpoint of engineering applications, the purpose of fatigue research consists of the
prediction of fatigue life on structures, increasing fatigue life and simplifying fatigue tests . All
these can be obtained by applying fatigue tests of full-scale structures under a random spectrum
load that give us more challenging for the real test .In reality, the most engineering components
and structures are subjected to variable amplitude loading conditions at which stressstrain
cycles fluctuate with time . At this condition, component tends to fail under various source of
loading. Fatigue failure of mechanical components is a process of cyclic stress/strain evolutions
and redistributions in the critical stressed volume In order to simplify the test; it then comes to
the application of related computational simulation. Using this technique, the fatigue life of
components can be firstly predicted before proceed to the durability test. One of the simulation
scope related to this issue is finite element analysis (FEA) approach.
Parabolic spring is widely used in automotive and one of the components of suspension system.
It consists of one or more leaves as a general rule, the leaf spring must be regarded as a safety
component as failure could lead to severe accidents.
Parabolic springs are subjected to cyclic compression and tension load when the truck was
drove on the road. In industry, manufacturer only manage to test the fatigue life of these spring
using constant amplitude loading.
This work is aim for the use related to an automotive industry, more specifically to parabolic
spring which is related to a suspension system, where safety is a great concern.
Parabolic spring was modeled using Catia software and analysis carried by abaqus.All the
specification is accordingly it consist of two leafs. As a preliminary study here, several
assumptions have been made i.e. the chosen material is homogenous, the frictional effect has not
been taken into account, shackle and bush is not model together to reduce the complexity of
simulation. Stresses and strains under different loads are analyzed.

Critical areas are obtained from the FEA. Finally, the life of this parabolic spring can be
predicted, showing the total life is lying within an acceptable limit.

FINITE ELEMENT ANALYSIS ON PARABOLIC LEAF SPRING IN SUSPENSION

SYSTEM

Fatigue failure of mechanical components is a process of cyclic stress/strain evolutions and

redistributions in the critical stressed volume .Therefore, the simulations for cyclic stress/strain
evolutions and redistributions are critical for predicting fatigue failure of mechanical
components.
Parabolic LEAF SPRING DESIGN METHODOLOGY
Every design method having CAE in the process must be based on validated virtual models. We have validated
our finite element analysis models by experimental studies. . Primary output obtained from finite element analysis.In
order to understand the parameters affecting fatigue strength of the leaf spring we have carried out a series of
experiments in varying conditions

2. LITERATURE SURVEY
Leaf springs absorb the vehicle vibrations, shocks andbump loads (Induced due to road
irregularities) by means of spring deflections, so that the potential energy is stored in the leaf
spring and then relieved slowly [1]. Ability to store and absorb more amount of strain energy
ensures the comfortable suspension system. Many suspension systems work on the same
principle including conventional leaf springs. However, for the same load and shock absorbing
performance, conventional
(steel) leaf springs use excess of material making them considerably heavy. This can be improved
by introducing composite materials in place of steel in the conventional spring. Studies and
researches were carried out on the applications of the composite materials in leaf spring [1,2]. A
composite mono leaf spring with an integral eye was manufactured and tested for the static load
conditions [2]. Fatigue life prediction was also done by authors so as to ensure a reliable number
of life cycles of a leaf spring. Further, a leaf spring had been modeled in conventional way and
simulated for the kinematic and dynamic comparatives [3]. Cyclic creep and cyclic deformation
was also studied [4]. Efforts were taken for Finite Element Analysis of multi leaf springs. These
springs were simulated and analyzed by using ANSYS 7.1[5]. Premature failure in leaf springs was
also studied so as to suggest remedies on application of composite leaf springs.

(REFERENCE Senthil kumar and Vijayarangan, Analytical and Experimental studies on Fatigue life Prediction of steel leaf soringand
composite leaf multi leaf spring for Light passanger veicles using life data analysis ISSN 1392 1320 material science Vol. 13 No.2
2007.)

scale drawing parabolic springs

FINITE ELEMENT ANALYSIS ON PARABOLIC LEAF SPRING IN SUSPENSION

SYSTEM
CAD Modeling of any project is one of the most time consuming process. One cannot shoot directly from the
form sketches to Finite Element Model. CAD Modeling is the base of any project. Finite Element software will
consider shapes, whatever is made in CAD model. Although most of the CAD Modeling software have
capabilities of analysis to some extent and most of Finite Element software have capabilities of generating a
CAD model directly for the purpose of analysis, but their off domain capabilities are not sufficient for large and
complicated models which include many typical shapes of the product. The model of the multi leaf spring
structures also includes many complicated parts, which are difficult to make by any of other CAD modeling as
well as Finite Element software. CAD modeling of the complete multi Leaf Spring structure is performed by
using CATIA V5 R17 software. CAD model of leaf spring consist of total 37 different parts which are
assembled together in assembly design to make a complete multi leaf spring model, out of all 37 parts, some
parts are similar in shape & size. The CAD model of multi leaf spring used for analysis is shown in Fig-5
below:All the boundary
conditions and material properties are specified as per the standards used in the practical application. The
material used for the leaf spring for analysis is structural steel, which has approximately similar isotropic
behavior and properties as compared to 65Si7
Parameters Exp. Results CAE Results Variation
Deflection 158 mm 156.15 mm 1.17%
Bending Stress 126 Kgf/mm2 141.56 Kgf/mm2 12.30%
Spring rate

The work is carried out on the front end leaf spring of a commercial vehicle. The objective of this work is to
carry out computer aided design and analysis of a conventional leaf spring, with experimental design
considerations and loading conditions. This conventional leaf spring model consists of 37 parts. The material of
the leaf spring is 65Si7.The CAD model of the leaf spring is prepared in CATIA and analyzed using ANSYS.
The CAE analysis of the leaf spring is performed for the deflection and stresses under defined loading
conditions, using ANSYS. The experimental and CAE results are compared for validation. Using CAE tools the
ideal type of contact and meshing element is determined in leaf spring model.
CAE tools are widely used in the automotive industries. In fact, their use has enabled the automakers to reduce
product development cost and time while improving the safety, comfort, and durability of the vehicles they
produce. The predictive capability of CAE tools has progressed to the point where much of the design
verification is now done using computer simulation rather than physical prototype testing.
Theoretical Leaf Spring Load
Deflection Diagram.

Parabolic springs have 2 or more leafs of varying widths that are only in contact at
the ends and middle of the spring pack. The advantage of this spring is that it can
react quickly to bumps and provide a much softer ride than standard leaf springs,
especially older leaf springs with rusted together leaves. If the weight range is
correct, the spring will articulate to both upper and lower limits of stock shock
travel. Properly set up these springs will provide almost coil spring like softness.
However since nothing comes for free there are a couple penalties that come with
the soft parabolic spring. One is an increase of side sway. Two to four leaves only
attached at the ends and middle have considerably less resistance to side torsion
than a block of leaves in constant contact along their lengths. So side sway on

FINITE ELEMENT ANALYSIS ON PARABOLIC LEAF SPRING IN SUSPENSION

SYSTEM
curves, from quick maneuvers and body tilts for terrain will be more, and the
dynamic centre of gravity will effectively be a little higher.
A more modern implementation of old leaf springs is the parabolic leaf spring for
automobiles. The new innovative design is characterized by the use of less leaves
whose thickness varies from the center to the outer side following a parabolic
pattern. This results in less inter leaf friction, because of which the only contact
point between the springs in vehicle is at the end and the center where the axle is
connected. Spacers used in the new design prevent the other parts collisions.
Besides being less in weight the main benefit of parabolic springs is their greater
flexibility, which is translated as a high ride quality of the vehicle. It gives us the
high ride quality which refers to the high degree of safety to the riders from the
uneven
road
surfaces
and
gives
high
level
of
comfort.
Modified version of leaf springs the parabolic leaf springs for automobiles has better
load bearing capacity with less weight. Other benefits include improved fuel
economy or load carrying capacity, cost effective, and reduced road damage for an
equivalent axle weight.