5 Leafspring

47
Working with Leaf Springs
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48 Getting Started Using Adams/Chassis
Overview
Adams/Chassis supports two types of leaf springs: SAE 3-link and beam element. This chapter
introduces you to the different types of leaf springs and contains two tutorials for modeling leaf springs
in Adams/Chassis.
• Working with SAE 3-Link Leaf Springs
• Working with Beam Element Leaf Springs
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Working with SAE 3-Link Leaf Springs

When you work with 3-link leaf springs, you use the VisEdit Property Spring Tab to display and edit
rotation spring and second stage rates, as shown Figure 14. The next two sections explain the data
displayed in the table.
Figure 14 Adams/Chassis Dataview Table
Rotational Spring Rates

• KT X = Longitudinal twist stiffness of that section (front or rear) of the spring. It is important
for roll stiffness.
• KT Y = Lateral bending stiffness of that section (front or rear) of the spring. It is important for
the lateral stiffness of the suspension.
• KT Z = Vertical bending stiffness of that section (front or rear) of the spring. This value is
important since it defines the spring rate of the spring.
• TO Z = The torque applied to the interleaf bushings (that is, front-to-middle link and middle-to-
rear link). This value is important in defining the spring rate of the leaf spring.
Second Stage Rates

• If the vehicle has a second stage (auxiliary leaf), Adams/Chassis models the second stage as a
single-component force (SFORCE) between the body and the axle.
• You can enter a simple linear rate (denoted by a positive value) or a nonlinear rate.
SAE 3-Link Leaf Spring Model Tutorial

This tutorial explains how to select the files associated with 3-link beam elements, integrate them into a
rear suspension, and run an analysis and view the results.
Note that you will use the model that you create here in next tutorial, Beam Element Leaf Spring Model
Tutorial. In the Beam tutorial, you will integrate a beam element spring in place of the 3-link leaf spring.
The tutorial takes about one hour to complete.
Loading Example Vehicle Database and System File

In this section, you will copy over an example vehicle database that uses a hotchkiss rear supension for
study.
1. From the Utilities menu, select Database Utilities.
2. Select the Find tool next to the Vehicle Database text box. Choose the big_truck.vdb
database by double-clicking the selection and selecting OK in the Selection dialog box.
Hint: The path is: <adams_install_directory>\achassis\examples\vehicles\big_truck.vdb
3. Select Copy Database to Working Directory.

4. Select OK at the prompt, and then close the Database Utilities window.
5. Select the Load Model button.
6. In the Select File window, select big_truck.vdb for the Registered Database.
7. Select big_truck_rear_sys.xml, and then select Open.
Viewing Leaf Spring Data

Before you run the simulation, view the data in the VisEdit Property Editor.
To view the data:

1. In the treeview, select big_truck_rst..
2. In the property editor, select the Springs tab as shown below.
3. View the data.
Figure 15 Leaf Spring Visual Editing Panel
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Running an Analysis
To run an analysis:
1. Select the Test mode.
2. In the bookshelf, expand Suspension, and the double-click Rear Ride Motion.
3. Select the rear ride motion event in the treeview, and then Build and Run Selected Events.
4. When the event is complete, close the command window.
Animating the Model
To animate the model:

1. Select the Review mode.
2. In the treeview, select big_truck_rear_sys_rride.
3. Select Execute Selected Animations.
4. From the dashboard, select the Play tool .
5. After the suspension goes through a complete animation, select the Pause tool .
6. Exit Adams/PostProcessor, and return to Adams/Chassis.
Modifying the Leaf Spring

You modify 3-link leaf springs using the same methods you have already learned for suspensions and full
vehicles: modify properties in the property editor, save the changes as a new file, and compare the
results.
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Working with Beam Element Leaf Springs

A beam element leaf spring model is a series of small parts connected by beams based on first principles.
Adams/Chassis provides a Leaf Spring Preprocessor in which you can quickly and efficiently prepare
the beam element leaf spring. You run the Preprocessor whenever you change the leaf properties.
The next sections explain more about working with beam element leaf springs and provide a tutorial that
steps you through the process of adding and analyzing leaf springs:
• Beam Element Leaf Spring Model Tutorial
• Viewing and Editing Beam Element Leaf Springs
The following is a flowchart that shows how to generate a model containing beam element leaf springs.
The tutorial, Beam Element Leaf Spring Model Tutorial, runs you through the steps needed to generate
the model in Adams/Chassis.
Figure 16 Flowchart for Working with Beam Element Leaf Spring Models
Gather Data
Measure the leaf spring geometry in the free
position.
Measure the mass of the shackle.
Measure the bushing rates of the three leaf

spring bushings.
Measure the height of the leaf spring leaf pack
Enter Data .ltf

Enter data in the leaf spring .ltf file.
Generate Model
Run Leaf Preprocessor to exercise leaf
model to design position.
Adams/Chassis creates a leaf .py file. It
contains parts, markers, beams, and so
on, that define the leaf spring.
Turn off the 3-link leaf spring and turn
on the beam element leaf spring in the
Flexible Parts table.
Viewing and Editing Beam Element Leaf Springs

Just as for the 3-link leaf spring, Adams/Chassis provides you with the ability to view and edit the
information defining the leaf spring. For beam springs, the editor is the Leaf Preprocessor. The next
sections explain the information about beam element leaf springs that you can view and edit in the Leaf
Preprocessor.
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• General Leaf Spring Information

• Axle
• Shackle
• Geometry
• Leaf Eyehook
• Bushing
• Leaf Profile
General Leaf Spring Information

You can view and edit the following general information about the beam element leaf spring:
• Number of leaves - The number of leaves in the model.
• Frictional coefficients - Leaf-to-leaf friction.
• Impact exponent - Level of impact.
• Leaf spring mounting - Where the leaf spring will be mounted in the vehicle. Used mainly for
part numbering.
• Fitting algorithm - Polynomial fitting of the leaf profile. (Generally, you use second order.)
Axle
For the axle, you can specify:
• Extra mass on dummy axle - The extra mass used to assemble the spring pack and connect it to
the axle.
• Reference marker to leafpack -The z height of the reference marker for the axle with respect to
the coordinate system used to define the profiles.
• Axle mount type - Either underslung or overslung, as shown in the following figure. If the
leaves are mounted above the axle, it is overslung. If the leaves are mounted below the axle, it is
underslung.
• Front and rear inactive lengths - Sections of the leaf spring regarded as rigid near the point
x=0.0.
• Reference marker height at design load - The z height of reference marker used to stop the
simulation. Once the axle reaches this point, it is at design load.
Figure 17 Illustration of Underslung and Overslung Leaves
Shackle
For the shackle, you can specify:
• Shackle length - The physical length of the shackle part, from eye center to eye center, specified
in millimeters.
• Shackle mass and inertia - The mass and inertial properties of the leaf spring shackle, in the
units shown.
• Shackle location - Whether the shackle is at the front or rear of the leaf spring pack.
• Shackle position - Whether the shackle is used in tension or compression. If the leaf eye is
below the shackle-to-body point, the link is in compression; if the leaf eye is above the shackle-
to-body point, the link is in tension.
Geometry
For geometry, you indicate points in space where the leaf springs will be constructed. Enter the x, y, and
z positions for both the front and rear chassis connection points. You must do this for both LEFT and
RIGHT springs.
You need another entry for the chassis contact points if you define an auxiliary leaf spring in the template.
This information is formatted such that it can be taken directly from the Adams/Chassis templates.
• Front leaf eye bushing - Corresponds to Points 1 and 2 in the subsystem file.
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• Shackle to frame - Corresponds to Points 20 and 21 in the file.
Leaf Eyehook
For the leaf eyehook, you can specify:
• Front and rear eyehook inner diameter - Diameter of the inside of the eyehook.
• Front and rear eyehook shape - The shape of the eyehook, as shown below.
Figure 18 Eyehook Shapes
Berliner Downturned Upturned

Eyehook Eyehook Eyehook
Bushing
For bushings, you specify the translational and rotational spring and damping rates. You can choose to
call the bushing spring rates from the subsystem file by turning on the flag in the lower right corner of
the Leaf Preprocessor. Calling the rate information from the subsystem file reduces bookkeeping, and
allows you to modify the bushings for variation studies.
The leaf-to-leaf bushings keep the leaves from moving laterally or twisting from each other. They should
have rather large values (~1.0 E+9 for translational rates and ~1.0 E+7 for rotational rates).
Leaf Profile
• Auxiliary leaf flag - Whether the leaf is defined as an auxiliary leaf (1) or not (0). The leaf flag
does not apply to Leaf 1, because Leaf 1 is always the leaf with eyehooks. The auxiliary leaf
should generally be the last leaf you specify. An auxiliary leaf is located on top of the leafpack
and, after the leaf spring has been compressed to a point, the auxiliary leaf contacts the chassis
and augments the spring pack.
• Z-offset - The sum of all previous leaf thickness and gap distances.
• Leaf length - The length of the front and rear sections of the leaf from the point x=0.0 defined in
the profile.
• # of elements (<=45) - The leaf being defined will be broken up into discrete sections, each of
which will be modeled using an MD Adams BEAM element (see the BEAM statement in the
online help for Adams/Solver.)
• Seat thickness and width - Thickness (z-direction) and width (y-direction) of the leaf being
defined at the point X=0.0.
• Emod, Gmod, density - Young’s modulus of elasticity (Emod), Shear modulus of elasticity
(Gmod), and density of leaf spring material. Used to define the beam statements and part
masses.
• ASY, ASZ - Correction factor for shear deflection in the y (ASY) and z (ASZ) directions,
according to Timoshenko beam theory.
• Damping ratio - The ratio for calculating the structural damping matrix for the MD Adams
beam. Adams/Solver multiplies the stiffness matrix by this value to obtain the damping matrix.
• X column - The position along the arc length of the spring, which is determined by flattening the
spring. Negative values are forward with respect to the vehicle.
• Z column - The curvature of the top of the spring at the points on the spring that correspond to x.
• Thickness column - The Thickness column defines the thickness of the leaf at each x value. The
column is flexible about the amount of data entered. You can define data only at desired points or
at all points. The only restriction is that you enter at least one value. Adams/Chassis processes
the data in the following way:
• Empty points between defined points are linearly interpolated.
• Empty points at the ends of the spring (outside of defined points) are held constant at the last
defined value.
• Number of contact points - Used to keep the leaves from passing through each other as they
deflect, in effect modeling the physical contact of the top of the current leaf with the bottom
surface of the one above it.
• Gap distance - The gap between the leaf and the one above it.
Tips for Using Beam Element Leaf Spring Models

• Increasing the thickness of the leaves increases the ride rate.
• Increasing the number of contacts between the leaves results in an increase in computational
time.
• You define two reference markers that are intended to move the leaf spring to design position:
• The reference marker height at design load is the height of the axle center at design.
• The reference marker to leafpack is the distance from the reference marker to the bottom
of an overslung leaf or the top of the underslung leaf. A positive number indicates overslung,
while a negative number indicates underslung. When Adams/Chassis builds the leaf spring, it
exercises the model until the reference marker to leafpack reaches the height, which is
the sum of the two heights. The leaf will be in its deformed position.
Beam Element Leaf Spring Model Tutorial

This tutorial creates a beam element leaf spring and incorporates it into a rear suspension. It shows you
how you use the Leaf Spring Preprocessor to generate all the necessary flexible parts (beam elements,
parts, markers, and so on) needed to define the leaf spring in your model.
The process for creating a model containing a beam element leaf spring includes gathering data and
entering the data in an.ltf file. For this tutorial, we’ve gathered the data for you and provided you with
a sample .ltf file called example.ltf.
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This tutorial builds upon the model you created in the tutorial earlier in this chapter, SAE 3-Link Leaf
Spring Model Tutorial. Therefore, be sure to run through that tutorial first.
The tutorial takes about one hour to complete.
Viewing the Leaf Spring

You will use the file, example.ltf, which contains a profile of a leaf spring. The leaf spring contains
four leaves.
To run the Leaf Preprocessor:

1. Copy example.ltf located in <achassis_install_dir>/examples/ltf into the springs.tbl folder in the
big_truck database in your working directory.
The data in example.ltf appears in the Leaf Spring Preprocessor, as shown in the following
figure.
2. From the Utilities menu, select the Leaf Spring Editor tool .
3. Select the Find tool for the .ltf text box.
4. Double-click the database to which you copied the example file, double-click springs.tbl, and
then select example.ltf.
Figure 19 Leaf Spring Preprocessor
General properties
about the entire leaf
Information
about each Plot of
leaf in the leaf
spring
springs
Note: If you modify the leaf spring, you must save the data before you select GO.
5. To view a plot of each leaf in the file, select each of the leaf tabs in the lower portion of the
Preprocessor.
Adams/Chassis highlights the selected leaf in the plot to the right.
6. View the general information about the leaf spring by selecting each tab at the top of the
Preprocessor. For explanations of the information displayed in each of the tabs, see Viewing and
Editing Beam Element Leaf Springs.
Running the Leaf Spring Preprocessor

To implement the leaf spring into your Adams/Chassis model, you must first run the Leaf Spring
Preprocessor. The Leaf Spring Preprocessor generates a file called example.py, which contains the
beam elements, parts, markers, and so on, needed to define the leaf spring in your model.
To run the Leaf Spring Preprocessor:

1. Select GO.
2. In the command window, at the prompt, select Enter.
3. To return to the Adams/Chassis main window, select Exit.
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Incorporating the Beam Element Leaf Spring into Your Model
To incorporate the spring into your model:

1. In the treeview, select big_truck_rst.
2. In the property editor, select the Springs tab.
3. Double click on sae3link_leafspring
4. Select Leaf_option
5. Select the Find tool next to the property file, and then select example.py.
6. Select Save as along the bottom, and save your new rear subsystem file as
hotch_beam.xml.
7. Select Yes to update references in the system file.
Running an Analysis and Animating It
To run an analysis of the model with a beam element leaf spring:

1. In the Test mode, expand Suspension in the bookshelf.
2. Double-click Rear-Ride Motion.
3. Select the event in the treeview, and then Build and Run the Selected Event.
Note that this analysis takes significantly longer to run than the 3-link beam analysis because the
model is more complex.
4. When the analysis is completed, close the command window.
To animate the model:

1. Switch to the Review mode.
2. Select the event in the treeview, and then select Execute Selected Animations.
3. Play the animation.
In the animation, you see many more elements than you saw in the previous 3-link leaf spring
model. Adams/Chassis modeled each leaf spring as a series of beam elements.
4. Return to the Adams/Chassis window.
Analyzing Effects of Leaf Spring Design Changes

Now you’ll use the model you created to examine the effect of leaf spring thickness on wheel rate. First,
you’ll change the thickness of Leaf 1 of the leaf spring, and then you’ll run an analysis and compare the
results of analysis with the previous analysis to see the effect of the different thicknesses.
To change the leaf spring thickness:

1. From the Utilities menu, select the Leaf Spring Editor.
2. Load the file example.ltf.
3. Select Leaf 1, and change its thickness to 13 mm by entering 13 in the Thickness column (third
column in the middle table).
For more information about the Thickness column, see Leaf Profile.
4. Select Save as, and change the name of your modified file to example2.ltf.
5. Rebuild the leaf model by selecting GO.
6. Select the rear suspension and select the new spring property.
7. Select Save as along the bottom, and save your new rear subsystem file as
hotch_beam2.xml.
8. To update references in the system file, select Yes.
9. To save the system file, select Save.
To run an analysis:
1. Switch to the Test mode.
2. Double-click the Rear Ride Motion event.
3. Select Build and Run Selected Events.
4. When the analysis is complete, close the window.
To plot the analysis results:

1. In the Review mode, select the two rear ride motion analyses in the fingerprint tree.
2. Verify that Overlay Plots/Reports of Same Events is selected.
3. Select Execute Selected Plots.
4. In the treeview of Adams/PostProcessor, select p03_Rear_Ride_motion.
Now you’ll view plots that show the effect of modifying Leaf 1’s thickness from 8 mm to 13 mm
on wheel rate.
5. Exit Adams/PostProcessor and Adams/Chassis.
As you can see from this tutorial, modeling with beam element leaf springs requires one additional
modeling step when investigating design changes.

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47

Working with Leaf Springs

Working with Leaf Springs

Working with SAE 3-Link Leaf Springs

Figure 14 Adams/Chassis Dataview Table

Rotational Spring Rates

Second Stage Rates

SAE 3-Link Leaf Spring Model Tutorial

The tutorial takes about one hour to complete.

Loading Example Vehicle Database and System File

Hint: The path is: <adams_install_directory>\achassis\examples\vehicles\big_truck.vdb

3. Select Copy Database to Working Directory.

Viewing Leaf Spring Data

To view the data:

Figure 15 Leaf Spring Visual Editing Panel

Animating the Model

To animate the model:

Modifying the Leaf Spring

Working with Beam Element Leaf Springs

Measure the mass of the shackle.

Measure the bushing rates of the three leaf

Measure the height of the leaf spring leaf pack

Enter Data .ltf

Viewing and Editing Beam Element Leaf Springs

• General Leaf Spring Information

General Leaf Spring Information

Figure 17 Illustration of Underslung and Overslung Leaves

• Shackle to frame - Corresponds to Points 20 and 21 in the file.

Figure 18 Eyehook Shapes

Berliner Downturned Upturned

Tips for Using Beam Element Leaf Spring Models

Beam Element Leaf Spring Model Tutorial

The tutorial takes about one hour to complete.

Viewing the Leaf Spring

To run the Leaf Preprocessor:

Figure 19 Leaf Spring Preprocessor

Running the Leaf Spring Preprocessor

To run the Leaf Spring Preprocessor:

Incorporating the Beam Element Leaf Spring into Your Model

To incorporate the spring into your model:

Running an Analysis and Animating It

To run an analysis of the model with a beam element leaf spring:

To animate the model:

Analyzing Effects of Leaf Spring Design Changes

To change the leaf spring thickness:

To plot the analysis results:

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