Design and Analysis of Leaf Spring Suspension of Mahindra ...
Transcript of Design and Analysis of Leaf Spring Suspension of Mahindra ...
International Journal of Scientific Research and Engineering Development-– Volume 4 Issue 4, July- Aug 2021
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Design and Analysis of Leaf Spring Suspension of Mahindra
Commander
Mayuresh Kulkarni *,Prathamesh Killedar **,Pravin Gosavi*** *Department of mechanical engineering, KIT’s college of engineering (Autonomous institute), Kolhapur
Email: [email protected]
** Department of mechanical engineering, KIT’s college of engineering (Autonomous institute), Kolhapur
Email:[email protected]
***Department of mechanical engineering, KIT’s college of engineering (Autonomous institute), Kolhapur
Email :[email protected]
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Abstract: This paper describes the design and analysis of leaf spring of steel material and composite material.
The objective of these paper is compare all composite materials and their load carrying
capacity ,strength ,weight savings of composite leaf spring over the steel leaf spring. The leaf spring
designed for MAHINDRA COMMANDOR 650di for weight 2150Kg.The CAD modeling of leaf spring
has been done on Solidworks and analysis is done on ansyssoftware.Objective is to find the equivalent
stresses and deformation, Equivalent strain of spring under static load conditions. The version of leaf
spring created in Solidworks in different four materials steel, carbon Fiber, Epoxy Carbon, E-glass. The
load action on spring considered as 537.5N.After comparative study we concluded that E-glass is more
suitable material than any other materials studied.
Keywords —leaf spring, composite material , conventional material, Mahindra commander
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I. INTRODUCTION
Multi-leaf spring are widely used for the suspension
of cars , trucks and railways wagons. It consist of a
series of flat plates in semi-elliptical shape .The flat
plates are called leaves of spring. The leaves are
held together by use of two U bolts and center clip.
Rebound clip provided to keep leavesin position or
in alignment and prevent lateral shifting during
operation. There are three types of leaves in leaf
spring. Master leaf ,full length leaves and graduated
level leaves. The master leave is called as longest
leaf, this leaf prevent the spring from both
end.Multi-leaf springs are provided with one or two
extra full length leaves in addition to master
leaf.And also have graduated length leaves are
forms one another group they treated as triangular
plate.
In this paper we try to design and analysis of leaf
spring and apply two materials one is steel and
another is glass jute which is composite
material .Now days automobile industries are
finding some innovation and some change in there
materials for the drawback they were faced with
the material. So by considering there researches and
requirements in the material used for leaf spring.
We are compared different materials one is
conventional and another is composite material .
what properties they having and which material is
better in future for suspension systems.
RESEARCH ARTICLE OPEN ACCESS
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Multi leaf spring diagram -:
II. LITERATURE REVIEW
1) M. Arther Clive from department of mechanical
engineering, SVS college of
engineering ,Coimbatore, Tamilnadu
compared deflection, equivalent stress, equivalent
elastic strain of carbon fiber, carbon epoxy, E
epoxy over conventional leaf springs in AutoCAD
2012. Mesh is created in Hypermesh software. They
done analysis of model in ANSYS 9.0. After
analysis they concluded that leaf spring of E
shows high deformation.
2)Sandip R Mundale, Prof.D.B.Pawar,
Prof.D.J.Verma presented a paper in which they
designed lead spring of Mahindra Commander in
CATIA software. They studied comparison
between steel, glass epoxy, carbon epoxy under
static load of 5375N. Analysis is done on ANSYS
software The deformation, stress and strain is
analyzed they concluded that composite material
used for leaf spring can reduce weight and stress.
3)G HarinathGowd from Sri S
Engineering College and E VenugopalGound from
Pullareddy engineering college presented work
presented work that attempts to analyze the safe
load of leaf spring from that comfortable speed with
safe drive can be decided. They choose TATA
light commercial vehicle for study. Finite Element
Analysis is done on ANSYS software. From results
they concluded max stress for given specifications
of leaf spring. Max stress is developed at inner side
of eye section
An easy way to comply with the conferen
paper formatting requirements is to use th
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1) M. Arther Clive from department of mechanical
engineering, SVS college of
engineering ,Coimbatore, Tamilnadu ,India
compared deflection, equivalent stress, equivalent
elastic strain of carbon fiber, carbon epoxy, E-glass
epoxy over conventional leaf springs in AutoCAD
2012. Mesh is created in Hypermesh software. They
done analysis of model in ANSYS 9.0. After
alysis they concluded that leaf spring of E-glass
2)Sandip R Mundale, Prof.D.B.Pawar,
Prof.D.J.Verma presented a paper in which they
designed lead spring of Mahindra Commander in
CATIA software. They studied comparison
l, glass epoxy, carbon epoxy under
static load of 5375N. Analysis is done on ANSYS
software The deformation, stress and strain is
analyzed they concluded that composite material
used for leaf spring can reduce weight and stress.
3)G HarinathGowd from Sri Shadevaraya
Engineering College and E VenugopalGound from
Pullareddy engineering college presented work
presented work that attempts to analyze the safe
load of leaf spring from that comfortable speed with
safe drive can be decided. They choose TATA-407
ht commercial vehicle for study. Finite Element
Analysis is done on ANSYS software. From results
they concluded max stress for given specifications
of leaf spring. Max stress is developed at inner side
An easy way to comply with the conference
paper formatting requirements is to use this
and simply type your text
DESIGN METHODOLOGY -
Leaf springs are also much studier as compared to
coil spring . They are capable of handling much
higher loads with less deflection than other coils of
the suspension which are used .Trucks with leaf
springs are also easier to raise or lower loads.
The solution for the problem is problems performed
in two stages-:
1)Design and analysis of leaf spring by applying
conventional steel material on spring .
2) Design and analysis of leaf spring by applying
composite materials on spring .
3) compare all analysis of the material which
used for leaf spring
Leaf spring of suspension system of MAHINDRA
COMMANDAR 650DI is designed by using
SOLIDWORKS 2019 with respective dimensions
of the vehicle. After that finaite element analysis is
done by using ANSYS 2021 R1.
Specifications for design of leaf spring of
MAHINDRA COMANDAR 650Di
For design and analysis of leaf spring all the
specification are consider of MAHINDRA
COMANDAR 650DiJeep . The specifications of
leaf spring are given in following table
Sr no Parameter name
1 Material
2 Leaf span (2L)
3 No of full length
leaves
4 No of graduated
leafs
5 Total no of
leaves
4 Width
7 Thickness
8 Young’s
modulus of leaf
spring
9 Ineffective
length
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-:
Leaf springs are also much studier as compared to
coil spring . They are capable of handling much
ion than other coils of
the suspension which are used .Trucks with leaf
springs are also easier to raise or lower loads.
olution for the problem is problems performed
Design and analysis of leaf spring by applying
conventional steel material on spring .
2) Design and analysis of leaf spring by applying
all analysis of the material which
Leaf spring of suspension system of MAHINDRA
COMMANDAR 650DI is designed by using
SOLIDWORKS 2019 with respective dimensions
of the vehicle. After that finaite element analysis is
YS 2021 R1.
Specifications for design of leaf spring of
MAHINDRA COMANDAR 650Di -:
For design and analysis of leaf spring all the
specification are consider of MAHINDRA
COMANDAR 650DiJeep . The specifications of
leaf spring are given in following table -:
Value
Steel EN45A
1120mm
No of full length 2
No of graduated 8
10
50mm
6mm
210000Mpa
100mm
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MATERIAL PROPERTIES:
Steel EN45 is conventionally used for leaf spring of
light weight vehicles. Steel EN45 has chemical
composition o.64% Carbon,0.4% Chromium,2.2%
Silicon,1% Manganese, 0.4%
Nickel,0.1%Molybdenum,0.04% Sulfur,0.035
Phosphorous which is generally used to
manufacture swards and knives.
steel EN45A
Young’s modulus[E] 210GPa
Ultimate tensile strength 1272 mPa
Poisson’s ratio 0.266
Yield strength 1158 mPa
Carbon Fiber:
Carbon Fibers are mostly composed of carbon
atoms and fibers having 5-10 micro meters in
diameter. It has high stiffness, high tensile strength,
high chemical resistance. It is mostly used in
aerospace industry and military applications.
Properties Value
Young’s modulus[E] 500GPa
Ultimate tensile strength 4000 mPa
Poisson’s ratio 0.17
Yield strength 2500 mPa
Epoxy Carbon:
Composite materials are made up of combination of
reinforced fiber with resin matrix. Due to extremely
strong carbon-carbon molecular bond they get high
strength
Properties Value
Young’s modulus[E] 110-120e+3 N/mm^2
Ultimate tensile strength 228e+3 MPa
Poisson’s ratio 0.27-0.30
Yield strength 1034 MPa
E-glass:
E glass is low alkali glass having composition of
Silicon Dioxide (52%-56%) , Calcium Oxide (16%
25%), Aluminum Oxide(12%-16%), Boron
Oxide(5%-10%), Sodium Oxide(2%) , Magnesium
Oxide(5%), Iron Oxide(0.05%-0.4%), Titanium
Oxide(0.8%), Fluorides(1%).It is mostly used for
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Steel EN45 is conventionally used for leaf spring of
light weight vehicles. Steel EN45 has chemical
composition o.64% Carbon,0.4% Chromium,2.2%
Nickel,0.1%Molybdenum,0.04% Sulfur,0.035
h is generally used to
EN45A
210GPa
1272 mPa
0.266
1158 mPa
Carbon Fibers are mostly composed of carbon
10 micro meters in
diameter. It has high stiffness, high tensile strength,
high chemical resistance. It is mostly used in
aerospace industry and military applications.
Value
500GPa
4000 mPa
2500 mPa
Composite materials are made up of combination of
reinforced fiber with resin matrix. Due to extremely
ar bond they get high
Value
120e+3 N/mm^2
228e+3 MPa
0.30
1034 MPa
E glass is low alkali glass having composition of
56%) , Calcium Oxide (16%-
16%), Boron
10%), Sodium Oxide(2%) , Magnesium
0.4%), Titanium
ostly used for
production of composite panels, surfboards, storage
tanks
Properties
Young’s modulus[E]
tensile strength
Poisson’s ratio
Yield strength
Dynamic specifications of Mahindra
COMMANDER 650 di Jeep:
Specification
Gross Vehicle weight
Wheel Base
Engine
Type Four stroke over square four
Wt of Engine
Wheel, Rim, Tyre
Track width
Turning Circle Radius
ANALYSIS OF LEAF Steel
First material is selected for analysis is
conventional structural steel. Results are given in
Following table.
Parameter:- Total
Deformation
Maximum
Minimum
Average 6.6978e
Parameter:- Equivalent
stress
Maximum
Minimum
Average
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production of composite panels, surfboards, storage
Value
76GPa
3400 MPa
0.30
3500
Dynamic specifications of Mahindra
COMMANDER 650 di Jeep:
Value
2150 kg
2680 mm
MD13000
Four stroke over square four
cylinder incline
275Kg
5 inches
3 mm
60mm
ANALYSIS OF LEAF SPRING:
First material is selected for analysis is
conventional structural steel. Results are given in
value
0.11442 mm
0 mm
6.6978e-0.002mm
Value
55.248 MPa
5.357e-007 MPa
5.316 MPa
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Parameter:-Equivalent
Elastic Strain
Value
Maximum 2.7682e-004 mm/mm
Minimum 3.1118e-012 mm/mm
Average 2.6885e-005 mm/mm
Carbon Fiber:-
Parameter:- Total
Deformation
Value
Maximum 2.188e-007 mm
Minimum 0 mm
Average 1.4587e-007 mm
Parameter:- Equivalent
stress
Value
Maximum 78.026MPa
Minimum 2.6311e-10MPa
Average 5.7552MPa
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Value
004 mm/mm
012 mm/mm
005 mm/mm
alue
007 mm
0 mm
007 mm
Value
78.026MPa
10MPa
5.7552MPa
Parameter:-Equivalent
Elastic Strain
Maximum 2.185e
Minimum 1.7539e
Average 1.3737e
Epoxy Carbon:
Parameter:- Total
Deformation
Maximum 3.2554e
Minimum
Average 2.1312e
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Value
2.185e-003 mm/mm
1.7539e-014 mm/mm
1.3737e-004 mm/mm
Epoxy Carbon:-
value
3.2554e-007 mm
0 mm
2.1312e-007 mm
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Parameter:- Equivalent
stress
Value
Maximum 67.698MPa
Minimum 3.9935e-9MPa
Average 5.6425MPa
Parameter:-Equivalent
Elastic Strain
Value
Maximum 2.9513e-
mm/mm
Minimum 2.8834e-
mm/mm
Average 1.7996-004
mm/mm
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Value
67.698MPa
9MPa
5.6425MPa
Value
-003
mm/mm
-013
mm/mm
004
mm/mm
E-Glass:-
Parameter:- Total
Deformation
Maximum 3.1341e
Minimum
Average 1.8359e
Parameter:-
Equivalent
stress
Value
Maximum 54.962MPa
Minimum 0.23611e
Average 5.3168MPa
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value
3.1341e-007 mm
0 mm
1.8359e-007 mm
Value
54.962MPa
0.23611e-6MPa
5.3168MPa
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Parameter:-Equivalent
Elastic Strain
Value
Maximum 7.5361e-004 mm/mm
Minimum 3.2349e-012 mm/mm
Average 7.3688e-005 mm/mm
CONCLUSION : Composite materials have high strength
ratio. They more stronger and stiffer than
conventional materials. Hence due to their
advantages like cost reduction, weight reduction
and recyclability composite materials are important
part of modern automotive industry. After
Analytical and Comparative study between total
deformation, equivalent stress, equivalent strain of
conventional steel, Carbon fiber, Epoxy carbon, E
glass it can be concluded that E-glass has better
deformation than other materials. Equivalent stress
of E-glass is also reduced than conventional
material.
REFERENCES [1] G. Harinath, and E. VenugopalGoud. "Static analysis of leaf spring."
International Journal of Engineering Science and Technology 4.8 (2012): 3794-3803
https://www.ijeat.org/wp-
content/uploads/papers/v2i3/C1061022313.pdf [2] Barnabas, J. Kingston. "Optimization of Leaf Spring parameters using
Taguchi’s DoE." (2020)
https://www.irjet.net/archives/V5/i6/IRJET-V5I6584.pdf
[3] Sandip R. Mundale, Prof. D.B.Pawar, Prof.D.J.Verma.“Design and
Analysis of Composite Leaf Spring using composite materi
weight vehicle.” International Journal of Advance Engineering and
Research Development. volume 4,Issue 12, December 2017.
https://issuu.com/editorijaerd/docs/design_and_analysis_of_composite
_le
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Value
004 mm/mm
012 mm/mm
005 mm/mm
Composite materials have high strength-to-weight
ratio. They more stronger and stiffer than
conventional materials. Hence due to their
advantages like cost reduction, weight reduction
and recyclability composite materials are important
otive industry. After
Analytical and Comparative study between total
deformation, equivalent stress, equivalent strain of
conventional steel, Carbon fiber, Epoxy carbon, E-
glass has better
Equivalent stress
glass is also reduced than conventional
G. Harinath, and E. VenugopalGoud. "Static analysis of leaf spring."
International Journal of Engineering Science and Technology 4.8
Barnabas, J. Kingston. "Optimization of Leaf Spring parameters using
V5I6584.pdf
Sandip R. Mundale, Prof. D.B.Pawar, Prof.D.J.Verma.“Design and
Analysis of Composite Leaf Spring using composite material for light
weight vehicle.” International Journal of Advance Engineering and
Research Development. volume 4,Issue 12, December 2017.
https://issuu.com/editorijaerd/docs/design_and_analysis_of_composite
Volume 4 Issue 4, July- Aug 2021
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