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Mahendra Engineering College Mallasamudram, Namakkal - 637503.

DESIGN AND ANALYSIS OF FIBER REINFORCEMENT POLYMER

Presented by, KISHORE KUMAR.M (Kishore.kumar0504@gmail.com) (vijaydinesh17@gmail.com) III YEAR MECHANICAL ENGG MECHANICAL ENGG 8903238397

DINESH.A

III YEAR CONTACT NO:

DESIGN AND ANALYSIS OF FIBER REINFORCE POLYMER (FRP) LEAF SPRINGWITH STEEL SLEVE LAYERS ABSTRACT This paper deals with design of composite leaf spring and sandwich composite leaf spring then the model is analyzed for the result of deflection, maximum bending stress induced for both same focusing material under while comparing with fully reinforced composite leaf spring. From the results, it is observed that the composite leaf spring is lighter and more economical than the conventional steel spring with similar design specifications. Excellent corrosion atmospheric resistance against

conditions. This paper mainly to use the sandwich composite &

leaf spring comparing composite

pollutants.Fully

conventional leaf spring. The model of the leaf spring is designed using modeling software and analysis is done using ANSYS10.0 software. Comparing with full epoxy material, steel inserted

interchangeable with the conventional spring without modifications Five times stronger than conventional metal leaf springs.

structure is better in design aspect of stress and deflection. There is 19% improvement in displacement and 27% improvement in bending stress in epoxy and steel sieve combination. In composite leaf spring having more deflection and also more bending stress under normal condition but in our designed sandwich spring has minimum deflection and bending stress. Hence it is works under safe mode of deflection and bending stress KEYWORDS: Composite leaf

spring, Composite Material, FRP, Finite Element Analysis, Fabrication technique.

INTRODUCTION: PROBLEM DEFINTION In leaf spring the major problem is weight which is not supported by the suspension system in heavy duty vehicles. Fatigue strength is also high. Shock absorption also occurs. And low fuel efficiency and life of the spring is very low. PROBLEM OCCURS More weight Low fuel efficiency Low life Low quality Fatigue performance is

heavy vehicles, a leaf spring can be made from several leaves stacked on top of each other on several layers, often with progressively shorter leaves. Leaf springs can serve locating and to some extent damping as well as springing functions. There were a variety of leaf the springs, word usually employing elliptical.

Elliptical or full elliptical leaf springs referred to two circular arcs linked at their tips. It takes the form of a slender arc-shaped length of spring steel of rectangular cross-section. The center of the arc provides location for the axle, while tie holes are provided at either end for attaching to the vehicle body. For very heavy vehicles, a leaf spring can be made from several leaves stacked on top of each other in several layers, often with progressively shorter leaves. Leaf springs can serve locating and to some extent damping as well as springing functions. While the inter leaf friction provides a damping section.

normal, High corrosion LEAF SPRING A leaf spring is a simple form of spring, commonly used for the suspension in wheeled vehicle. It is also one of the oldest forms of springing, dating back to medieval times. The advantages of leaf spring over helical spring are that the end of the springs may be guided along a definite path. The center of the arc provides location for the axle, while tie holes are provided at either end for attaching to the vehicle body. For very

Fig 1.1 Actual leaf spring FIBRE SPRING An FRP leaf spring which comprises a plurality of continuous fibers arranged to extend within a number of adjacent thickness ranges of the leaf spring, and a resin in which said plural continuous fibers are embedded, said continuous fibers being of such diameter as corresponds to the position of that thickness range of the leaf spring in which said fibers are embedded, wherein the fibers in each said thickness ranges have a diameter which is different from the diameters of the fibers in a next adjacent thickness range. The FRP leaf spring thickness is divided in to plurality of layers, and wherein finer fibers are embedded in that layer of the leaf spring which lies nearer to the surface of the leaf spring to which a tension stress is applied. two SANDWICH COMPOSITE LEAF SPRING A sandwich is defined as two or more piece of material is placed between each pair. In our paper sandwich name will indicate that steel sieve inserting between middle portions of the COMPOSITE LEAF Fig 1.2 Fiber composite leaf spring

composite leaf spring. By using of steel its having high bending stress and high strength. COMPOSITES A composite is a combination of or more materials having

compositional variations and depicting properties distinctively different from those of the individual materials of the composite. The composite material is generally better than any of the individual components as regards their strength, heat resistance or stiffness.

Each of these constituent materials or ingredients play an important role in the processing and final performance of the product. The resin or polymer is the glue that holds the composite together and influences the physical properties of the end product. The reinforced provides the mechanical strength. Advantages High stiffness-to-weight and

acts as a load transfer medium between them, and protects them from

environment damages due to elevated temperatures and humidity. The most common form in which fiber reinforced composite are used in structural applications is called a laminates, which is made by stacking a number of thin layers of fiber and matrix and consolidating them into the desired thickness. FIBER The fiber is a filament or threaded like piece of any materials. Fibres are the principal constituents in a fiber reinforced composite material. They

strength-to-weight ratio. Elimination of corrosion and stress corrosion problems. Significant reduction in fatigue problems Improved control of surface

occupy the largest volume fraction in a composite laminate and share the major portion of the load acting on a

contour and smoothness FIBER-REINFORCED COMPOSITE Fiber-reinforced composite

composite structure. GLASSFIBERS Based on a alumina-lime-borosilicate composition, Eglass produced fibers are considered for the predominate matrix

materials consist of fiber of high strength and modulus embedded in or bonded to a matrix with distinct interface between them. Fiber are the principal load carrying members while the surrounding matrix keeps them in the desired location and orientation,

reinforcement

polymer

composites due to their high electrical insulating properties, low susceptibility to moisture and high mechanical commercial

properties.

Other

compositions include Sglass, with higher strength, heat resistance and modulus, as well as some specialized glass reinforcements with improved chemical resistance, such as AR glass (alkali resistant). glass fibers are in various form:-

Continuous roving Woven roving Chopped strand

strand

Chopped strand mat Woven roving mat

EPOXIES Epoxies represent some of the most versatile resins available to the composite manufacturer. Epoxy resins have a well established record in a wide range of composite parts,

No permanent deformation hence no re-cambering, thus no

maintenance. Minimum wear and tear of body parts and tyre due to delicate tensency of absorbing road shocks, jerks and vibrations. Softer ride, Lower noise level, excellent stability due to better damping characteristics. Excellent Five corrosion resistance

structures and concrete repair. The structure of the resin can be

engineered to yield a number of different products with varying levels of performance. Starting materials for epoxy matrix are low molecular weight organic liquid resins

against atmospheric pollutants. times stronger than

containing a number of epoxies groups which are the three member of rings of one oxygen atom and two carbon atoms. A major benefit of epoxy polyester resins resins over is unsaturated their lower

conventional metal leaf springs. Fully interchangeable with the conventional modifications. Increase in fuel efficiency due to better aerodynamics and around 60% weight reduction. No cracking sound since mono leaf and hence no inter-leaf friction and no greasing required. APPLICATION OF FIBREspring without

shrinkage. Epoxy resins can also be formulated with different materials or blended with other epoxy resins to achieve specific performance features. PROPERTIES OF FRP LEAF SPRING: Give effects like Air Suspension without any extra external energy (Fuel).

REINFORCED COMPOSITES The composites produced and their applications in the U.S can be appreciated from the statistics.

Production figures from 1978 are shown as well, as a better historical perspective can thus be gained. It should be kept in mind that the numbers will be influenced by the economy, so that the numbers will be influenced by the economy, so that while marine applications may have substantially increased, the pleasure boat market may have decreased. The applications of fibrous composites extends their hand in the areas of cryogenic fuel tank, high performance cars, unmanned aerial vehicle, fiber glass tank and tubes, wind turbine blades, civilian aircraft, composites. high temperature

software and analysis is done using ANSYS10.0 software.

DESIGN DRAWING DESIGN Flexural rigidity is an

important parameter in the leaf spring design, and it should

increase from two ends of the spring to its center. This idea gives different possibilities, cross-section width with types of design constant constant thickness

namely, design, varying

design, and constant thickness with varying width design. The constant cross-section design is selected due to its capability for mass

production, and to accommodate METHODOLOGY This paper deals with design of composite leaf spring and continuous reinforcement of fibers. The design of composite leaf spring aims at the replacement of seven-leaf steel spring of an automobile with a mano-leaf

sandwich composite leaf spring then the model is analyzed for the result of deflection, maximum bending stress induced for both material under same conditions. The model of the leaf spring is designed using modeling

composite spring. The design requirements are taken to be identical to that of the steel leaf spring: Design load, w=6000N

Maximum allowable vertical deflection,max =130 Distance between eyes in straight condition, L=1000mm. Spring rate k=28-32N/mm. The composite leaf spring is designed to cater the above requirements based on the design procedure given in the literature.

THREE DIMENSIONAL FINITE ELEMENT ANALYSIS To design sandwich composite leaf spring, a stress analysis was performed using the finite element method using the finite element method done using ANSYS software. Modeling as done for every leaf with SOLID95-3D solid element 20 node and SOLID45-3D solid element 8 node used to represent contact and sliding between adjacent surfaces of leaves. Also, carried out for composite leaf spring with bonded end joints for GLASS/EPOXY, composite material and the results were compared with steel leaf spring with eye end. The

2D DRAWING

maximum peel and shear stresses along the adhesive layer were measured Represent FEA results for steel and mano composite leaf

spring (glass/epoxy).the maximum peel and shear stresses along the bonded adhesive layer for glass/epoxy were measured and plotted as shown in figs.

3D HALF LEAF SPRING ANALYSIS

CONCLUSION

Un-Deformed Shape

The sandwich composite leaf spring is designed according to variable cross-section area method. The 3-d model of sandwich leaf spring is analyzed using ANSYS software. The results of the sandwich leaf are comparing with existing normal leaf springs. From the results, it is observed that In composite leaf spring having more deflection and also more bending stress under normal load condition Deformed Shapebut in our designed sandwich spring has minimum deflection and bending

SUMMARY OF ANALYSIS RESULT Comparing with full epoxy material, steel inserted structure is better in design aspect of stress and deflection. There is 19% improvement in displacement and

stress. Hence it is works under safe mode of deflection and bending stress while comparing with fully reinforced composite leaf spring. -Thanking you

27%improvement in bending stress in epoxy and steel sieve combination. E-Glass Fiber & Epoxy with Steel Sieve is recommended to implement.

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