IJSTE - International Journal of Science Technology & Engineering | Volume 1 | Issue 11 | May 2015

ISSN (online): 2349-784X

Static and Dynamic Analysis of Automobile Leaf

Spring (TATA ACE)
Trivedi Achyut V.
M. Tech CAD/CAM
Department of Mechanical Engineering
Marwadi Education Foundations Group of Institution
Rajkot-360007,India

Prof. R.M. Bhoraniya

Professor
Department of Mechanical Engineering
Marwadi Education Foundations Group of Institution
Rajkot-360007,India

Abstract
The Automobile firm has shown greater interest for replacement of conventional steel leaf spring with that of composite leaf
spring, as the composite material has high strength to weight ratio, good corrosion resistance. The objective of this work is to
compare the load enhancing capacity, and weight savings of composite leaf spring with respect to conventional steel leaf spring.
The dimensions of an existing conventional steel leaf spring of a Light design calculations. Static Analysis of 3-D model of
conventional leaf spring is performed using analysis commercial software. And that dimensions are used for composite multi
leaf spring as well by taking composites as carbon/Epoxy and Graphite/Epoxy . The constraints are stress and deformation and
weight of composite leaf spring with respect to conventional steel leaf spring. For static condition static analysis done and for
real time problem dynamic analysis work present here.
Keywords: Leaf Spring, Dynamic Analysis
________________________________________________________________________________________________________

I. INTRODUCTION
Insight to take maximum advantages of natural resources and also to economize the energy, weight reduction has been the main
area of focus for an automobile manufacturer in the today scenario. Initially Weight can be reducing by the introduction of better
material, doing design optimization and by applying better manufacturing processes. The suspension system element termed as
leaf spring is one of the critical part for weight reduction in automobile as it takes ten to twenty percent of the unstrung weight.
That can been helpful to achieve the vehicle been improved riding qualities. As we know that springs, are mainly designed to
absorb (catch-up) and store energy and then when it need it can release that energy. In that, the strain energy (for spring) of the
material can become a major part in designing the springs.
Main proposes for the introduction of composite materials mainly was made it possible for reduction into the weight of the
leaf spring, without any reduction on load carrying capacity and stiffness. As we all know that the composite materials having
more elastic (strain) energy storage capacity and high strength-to-weight ratio with respect to those of steel.
Multi-leaf springs are more used for automobile and sometime for rail road suspensions. It has a geometry which consist a
series of flat plates, usually having a semi- elliptical shape as shown in fig. 1.1. As shown in figure the leaves are held together
with the help of two U-bolts and also centre clip. Also in that Rebound clips are provided to keep the leaves in alignment and
save from lateral shifting of the plates during the working condition. The leaf having maximum length, called the master leaf,
master leaf is bent at both ends to form the spring eye part.

Fig. 1: Leaf Spring

At the center position, the spring is fixed to the main axle (front or rear) of the car. Mainly Multi- leaf springs are provided
with one or mostly with two extra full length leaves in addition to the master leaf. These extra full-length leaves can be stacked
between the master leaf having maximum length and the graduated-length leaves. The extra full-length are provided to support
the transverse shear force acting on the component.
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Static and Dynamic Analysis of Automobile Leaf Spring (TATA ACE)

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II. WORKING PRINCIPLE OF LEAF SPRING

The suspension system having main element termed as leaf spring is one of the potential and very critical term for weight
reduction in automobile industries as its having a ten to twenty percent of the unsprung weight. By introducing composites, it can
helpful for design a better suspension system having a better ride quality but the condition is it must be achieved without much
increase cost and also decrease quality and reliability. In the design of springs, strain energy becomes the major factor. The
relationship of the specific strain energy can be expressed as
U=2/Eeq. (1.1)
Where = strength,
=density
E =Youngs Modulus of the spring material
It can be noted that material which is having a lower modulus and also having a lower density will have a greater specific
strain energy capacity. So the introduction of composite materials can made it possible to reduce the weight of the leaf spring
without any reduction into the load carrying capacity and stiffness. A Composite mainly is any materials that have been
physically assembled to form one single bulk without physical blending to foam a homogeneous material.
The resulting
material would still have components identifiable as the constituent of the different materials. One of the advantages of
composite is that two or more materials could be combined to take advantage of the good characteristics of each.
Fig. 1.2 shows an Arrangement of leaf spring into a car Model a spring eye section is used to attach the front end of semielliptic shape leaf spring to the chassis frame, and a free end having a bracket constraining vertical motion to attach the back end
of semi-elliptic leaf spring to the chassis frame.

Fig. 2: Arrangement of Leaf Spring in Car Model

III. SPECIFICATION OF LEAF SPRING

Forces acting on leaf spring are as shown in fig. Main forces acting on leaf spring are as follow but in this analysis only vertical
loading condition is considered. Forces acting on leaf spring:
Vertical loading (Fv)
Side load (Fs)
Longitudinal load (Ft)
Twisting torque (Tt)
Windup torque (Tw)

Fig. 3: Load Acting on Leaf Spring

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Static and Dynamic Analysis of Automobile Leaf Spring (TATA ACE)

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A. Assumptions for Analysis:

Automobile is assumed to be stationary.

There are 2Semi-elliptic leaf spring, one at front and one at rear axle. And for Only vertical loading.
Static analysis is carried out for rear single semi-elliptic leaf spring.

IV. ANALYSIS OF LEAF SPRING

The leaf spring having specification as shown in table 1 initially static analysis done on leaf spring by considering leaf spring as
a simple supported beam and design constraints are stress and deformation. The result as show in figure . analysis done on ansys
and for validation mathematical calculation done. For real time problem the dynamic (Modal analysis ) considered for time
period of 5s. the purpose of this work is to avoid the resonance occur with new leaf spring.
Table 1
Specification of TATA ACE Leaf Spring

Sr.no
1
2
3
4

Design parameter
Total length of spring(L)
Length of spring from eye to eye
Thickness(t)
Width of leaf spring(b)

Value
930mm
754mmm
8mm
60mm

1)

Specification of TATA ACE [15]

Weight of vehicle = 500 Kg

Maximum load carrying capacity = 325 Kg
Total weight = 500+325
So , total weight = 825 Kg
Static load apply on vehicle = 825*9.81 N
So , static load apply on vehicle 8000 N (approx.)
At every wheel load = 2000 N and same as reaction force = 4000 N at downward point.

Table 2
Material Properties of Conventional Material

Material selected[10]

65si7

Youngs Modulus,(E)
Poissons Ratio
Tensile Yield strength

2.1*105 N/mm2
0.266
250 MPa

Density

7850 Kg/m3

Behavior

Isotropic

Fig. 4: Model of Leaf Spring (TATA ACE)

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Static and Dynamic Analysis of Automobile Leaf Spring (TATA ACE)

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Fig. 5: Stress in Conventional Material

Fig. 6: Deflection in Conventional Material

Table 3
Composites Material Properties
Material selected[15]
E-Poxy
Exx
34000 MPa
Eyy
6530 MPa
Ezz
6530 MPa
Poisons ratio along XY
0.217
Poisons ratio along YZ
0.366
Poisons ratio along XZ
0.217
Gxy
2433 MPa
Gyz
1698 MPa
Gxz
2433 MPa
Density of material
2.6*1000 kg/mm3
orthotropic
Behavior

Fig. 7: Stress in Composites Material

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Static and Dynamic Analysis of Automobile Leaf Spring (TATA ACE)

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Fig. 8: Deflection in Composites Material

1)

Mathematically Validation:
By considering beam equation[16]:
As Maximum deflection can be given by: (X=L)

Max. deflection =
Max. deflection = 0.06459 m
Table 4
Analytical and Ansys Result Comparison
Material
Deformation (m)
Error (%)
Analytical Simulation
Conventional steel
0.06459
0.05616
2.1
Table 5
Analytical and Ansys Result Comparison
Material Stress (Pa) Deformation (m) Mass (Kg)
65si7
5.8739e8
.006
5.45
E-Poxy
4.74e8
0.05616
1.8

Fig. 7: Frequency and Deformation at Mode 5

Fig. 8: Modal Analysis at 5s for Forced Vibration

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Static and Dynamic Analysis of Automobile Leaf Spring (TATA ACE)

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Table 6
Comparing Frequencies for Resonance Effect
Frequency(Hz) Natural frequency(Hz)
Sr. no
For max modal shape at 5s time
655
598

V. CONCLUSION
In this research we can conclude that with respect to conventional steel leaf spring composites having high strength to weight
ration. Also composites having nearly 400% less weight than conventional steel leaf spring. And also from Modal analysis we
can conclude that composite leaf spring is safe as its not showing resonance effect so its safe in that manner.

REFERENCES
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[5]

Mahmood M. Shokrieh , Davood Rezaei Analysis and optimization of a composite leaf spring, Composites Research Laboratory, Department of
Mechanical Engineering, Composite Structures 60 (2003) 317325
B.Vijaya Lakshmi & I. Satyanarayan, Static and dynamic analysis on composite leaf spring in heavy vehicle , International Journal of Advanced
Engineering Research and Studies ,Vol. 2, Issue Oct.-Dec.,2012, 80-84
I.Rajendran ,& S.Vijayarangan , optimal design of a composite leaf spring using genetic algorithms, computers & structures 79(2002) 1121-1129

M. Raghavedra,& Syed Altaf Hussain, Modeling and Analysis of Laminated Composite Leaf Spring under the
Static Load Condition by using FEA International Journal of Modern Engineering Research (IJMER) www.ijmer.com
Vol.2, Issue.4, July-Aug. 2012, 1875-1879 ISSN: 2249-6645
H.A.Al-Quereshi Automobile leaf spring from composite materials, journal of material processing technology, 118(2001), 58-61

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