| Design,
Analysis, Fabrication And Testing Of A Composite Leaf Spring |
Definition
In order to conserve natural
resources and economize energy, weight reduction has been the main focus of automobile
manufacturers in the present scenario. Weight reduction can be achieved primarily
by the introduction of better material, design optimization and better manufacturing
processes. The suspension leaf spring is one of the potential items for weight
reduction in automobiles as it accounts for 10% - 20% of the unsprung weight.
This achieves the vehicle with more fuel efficiency and improved riding qualities.
The introduction of composite
materials was made it possible to reduce the weight of leaf spring without any
reduction on load carrying capacity and stiffness. Since, the composite materials
have more elastic strain energy storage capacity and high strength to weight ratio
as compared with those of steel, multi-leaf steel springs are being replaced by
mono-leaf composite springs. The composite material offer opportunities for substantial
weight saving but not always be cost-effective over their steel counterparts. Literature
Review Investigation of composite leaf
spring in the early 60's failed to yield the production facility because of inconsistent
fatigue performance and absence of strong need for mass reduction. Researches
in the area of automobile components have been receiving considerable attention
now. Particularly the automobile manufacturers and parts makers have been attempting
to reduce the weight of the vehicles in recent years. Emphasis of vehicles weight
reduction in 1978 justified taking a new look at composite springs. Studies are
made to demonstrate viability and potential of FRP in automotive structural application.
The development of a liteflex suspension leaf spring is first achieved. Based
on consideration of chipping resistance base part resistance and fatigue resistance,
a carbon glass fiber hybrid laminated spring is constructed. A general discussion
on analysis and design of constant width, variable thickness, composite leaf spring
is presented. The fundamental characteristics of the double tapered FRP beam are
evaluated for leaf spring application. Recent developments have been achieved
in the field of materials improvement and quality assured for composite leaf springs
based on microstructure mechanism. All these literature report that the cost of
composite; leaf spring is higher than that of steel leaf spring. Hence an attempt
has been made to fabricate the composite leaf spring with the same cost as that
of steel leaf spring. Material properties
and design of composite structures are reported in many literatures. Very little
information are available in connection with finite element analysis of leaf spring
in the literature, than too in 2D analysis of leaf spring. At the same time, the
literature available regarding experimental stress analysis more. The experimental
procedures are described in national and international standards. Recent emphasis
on mass reduction and developments in materials synthesis and processing technology
has led to proven production -worthy vehicle equipment. Materials
Selection Materials constitute nearly 60%-70%
of the vehicle cost and contribute to the quality and the performance of the vehicle.
Even a small amount in weight reduction of the vehicle, may have a wider economic
impact. Composite materials are proved as suitable substitutes for steel in connection
with weight reduction of the vehicle. Hence, the composite material have been
selected for leaf spring design.
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