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07/09/16
1.Objective
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.
Factors like fatigue life, fatigue damage, biaxiality indication etc.
are plotted for steel and composite materials and predict the
fatigue performance using ANSYS Workbench software.
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.
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2. Background
Author
Conclusion
Senthilkumar
Mouleeswaran [2]
D.N.Dubey,
S.G.Mahakalkar [7]
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2. Background
Author
Conclusion
Shishay Amare
Gebremeskel [4]
J.A.M. Ferreira,
J.D.M. Costa,
P.N.B. Reis, M.O.W.
Richardson [8]
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Value
1200 mm
120 mm
Thickness of leaf
8 mm
60 mm
3250 N
01
04
SAE1045-450-QT
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Material Properties
Value
207
34000
1515
6530
1584
6530
1874
900
1686
-0.06
450
-0.83
2433
0.79
1698
0.09
2433
Density , Kg/m
7.7 10
0.217
0.366
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Material Properties
Value
Possions ratio
0.266
Behaviour
Isotropic
Front Eye
Rear Eye
Translation
X, Y & Z direction
Y & Z direction
X & Z direction
X & Z direction
Free Y rotation
Constrained
Rotation
Constrained
Allowing
Y rotation
Table. 4 : Boundary condition Mono Leaf
Spring
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Maximum
SAE1045-
E-Glass Epoxy
450-QT
Composite
3250
3250
724.52
715
24.33
53.59
Stress , MPa
Stiffness, N/mm
Static Results :
Shear stress (12= 6.77 MPa) multiplied
by a factor of 9 (9*3 = 60.93 MPa) is
much less than the shear strength (S =
68.95 MPa) of the specified composite
material, E-glass/Epoxy.
Specifying the criteria : (9*12< S),
Design is safe even for the flexural
Table 6 Natural frequency of SAE 1045-450-QT and
failure. E-Glass Epoxy Composite material
SAE1045-450- QT
E- Glass Epoxy
Frequency Hz
Frequency Hz
13.13
17.15
54.55
56.16
78.59
72.19
116.89
119.36
178.49
202.78
243.27
288.43
Modes
Ride Comfort :
To avoid resonant condition The road
irregularities usually have the
maximum frequency of 12 Hz. [7]
In modal analysis only boundary
conditions are applied and no load is
acted on the leaf spring.
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10
11
(1)
max
= maximum stress ;
(3)
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12
The life data analysis is a tool to be used here to predict the fatigue
life of mono composite leaf spring.
Fatigue life results are based on analytical result and resulting S-N
graph for SAE1045-450-QT and E Glass Composite as shown in
Fig. 7 and 8
E glass-epoxy figure is for tension, torsion or bending ? Specify !
( Figure 7)
13
1.025*105 cycles
1.725*109 cycles
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14
15
16
Biaxiality Indication
Biaxiality indication is defined as the
smaller principal stress divided by the
larger principal stress with the principal
stress nearest zero ignored
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18
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9. References
1.
2.
3.
4.
5.
6.
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9. References
7.
8.
J.A.M. Ferreira, J.D.M. Costa, P.N.B. Reis, M.O.W. Richardson, Analysis of fatigue and
damage in glass-fibre-reinforced polypropylene composite materials, Composites
Science and Technology 59 (1999), 1461-1467
9.
10.
11.
12.
13.
Sachin Kr. Patel, A.K. Jain and Pratik Gandhi, Review of Effect of Material on Fatigue
Life of Leaf Spring, VSRD International Journal of Mechanical, Civil, Automobile and
Production Engineering, Vol. 2 (4), 2012, 161-165
Mahmood M. Shokrieh , Davood Rezaei, Analysis and optimization of a composite
leaf spring , Composite Structures 60 (2003), 2003 Elsevier Science Ltd, 317325
J. P. Karthik, K. L. Chaitanya and C. Tara Sasanka, Fatigue Life Prediction of a
Parabolic Spring under Non-constant Amplitude Proportional Loading using Finite
Element Method, International Journal of Advanced Science and Technology, Vol. 46,
September, 2012, 143-156
M.Venkatesan , D.Helmen Devaraj , Design And Analysis of Composite Leaf Spring
In Light Vehicle, International Journal of Modern Engineering Research (IJMER), ISSN:
2249-6645, Vol.2, Issue.1, Jan-Feb 2012, pp-213-218
D. Alfred Hancq, Fatigue Analysis Using ANSYS, Ansys Inc, year ? Vol ?, Issue ? Page ?
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Thank you
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