International Journal of Mechanical and Production

Engineering Research and Development (IJMPERD)

ISSN 2249-6890
Vol. 3, Issue 3, Aug 2013, 1-8
TJPRC Pvt. Ltd.

COMPARATIVE STUDY OF SINGLE LEAVE LEAF SPRING IN CAE TOOL AND

EXPERIMENTAL DATA OF LEAF SPRINGS IN AUTOMOTIVE VEHICLES
S. D. RATHOD1, D. S. SHAH2 & S. A. BAN3
1

ME CAD/CAM (Mechanical), IVth Semester, SVIT Vasad, Gujarat India

2,3

Assistant Professor, Mechanical Department, SVIT Vasad, Gujarat, India

ABSTRACT
The work is carried out on the front end leaf spring of a commercial vehicle. The objective of this work is to Carry
out computer aided design and analysis of a elliptical single leave leaf spring, with experimental design considerations and
loading conditions. The material of the single leave leaf spring is 65Si7.The CAD model of the single leave leaf spring is
prepared in Solid-Works and analyzed using ANSYS-14.0. The CAE analysis of the single leave leaf spring is performed
for the deflection and stresses under defined loading conditions, using ANSYS-14.0. The experimental and CAE results are
compared for validation. Using CAE tools the ideal type of contact and meshing element is determined in leaf spring
model.

KEYWORDS: Computer Aided Engineering (CAE), Leaf Spring, 65Si7, Static Loading, Finite Element Analysis, FEM
INTRODUCTION
CAE tools are widely used in the automotive industries. In fact, their use has enabled the automakers to reduce
product development cost and time while improving the safety, comfort, and durability of the vehicles they produce. The
predictive capability of CAE tools has progressed to the point where much of the design verification is now done using
computer simulation rather than physical prototype testing. CAE dependability is based upon all proper assumptions as
inputs and must identify critical inputs. Even though there have been many advances in CAE, and it is widely used in the
engineering field, physical testing is still used as a final confirmation for subsystems due to the fact that CAE cannot
predict all variables in complex assemblies, therefore the validation of CAE results is important.
The specimen under this research work consists of single leave elliptical leaf spring etc. CAE tools are being used
to analyze the robustness and performance of single part. The finite element analysis (FEA) is a computing technique that
is used to obtain approximate solutions to the boundary value problems in engineering. It uses a numerical technique called
the finite element method (FEM). Using FEA single leave leaf spring is modeled using the discrete building blocks called
elements. Each element has some equations that describe how it responds to certain loads. The sum of the response of all
the elements in the model gives the total response of the design. CAE tool depends upon actual assumptions of the parts
which act as input data. CAE has become an important technology with benefits such as lower costs and a shortened design
cycle. Studies say that any design professional can save approximate 30% of time and cost by using CAE tools. In future
CAE system will be major information provider to help design professionals in decision making. Mouleeswaran et al [1]
describes static and fatigue analysis of steel leaf spring and composite multi leaf spring made up of glass fiber reinforced
polymer using life data analysis.
The dimensions of an existing conventional steel leaf spring of a light commercial vehicle are taken and are
verified by design calculations. Static analysis of 2-D model of conventional leaf spring is also performed using ANSYS

S. D. Rathod, D. S. Shah & S. A. Ban

7.1 and compared with experimental results. Hawang W et al [2] Fatigue of Composites Fatigue Modulus Concept and
Life Prediction Journal of Composite Materials.H. A. Al-Qureshi et al [3] has described a single leaf, variable thickness
spring of glassfiber reinforced plastic (GFRP) with similar mechanical and geometrical properties to the multileaf steel
spring, was designed, fabricated and tested. J.J.Fuentes et al [4] in this work, the origin of premature failure analysis
procedures, including examining the leaf spring history, visual inspection of fractured specimens, characterization of
various properties and simulation tests on real components, were used. Rajendran I, S. Vijayarangan et al [5] A
formulation and solution technique using genetic algorithms (GA) for design optimization of composite leaf springs is
presented here.
Gulur Siddaramanna et al [6] explain the automobile industry has shown increased interest in the replacement of
steel spring with fiberglass composite leaf spring due to high strength to weight ratio. Therefore; the aim of this paper is to
present a low cost fabrication of complete mono composite leaf spring and mono composite leaf spring with bonded end
joints. J.P. Hou et al [7] explained the design evolution process of a composite leaf spring for freight rail application.
Peiyong et al [8] describes that the Leaf spring design was mainly based on simplified equations and trial-and-error
methods.
The simplified equation models were limited to the three-link mechanism assumption and linear beam theory.
This work presents detailed finite element modeling and analysis of a two-stage multi-leaf spring, a leaf spring assembly,
and a Hotchkiss suspension using ABAQUS. Muhammad Ashiqur et al [9] describes that the tapered cantilever beams,
traditionally termed as leaf springs, undergo much larger deflections in comparison to a beam of constant cross-section that
takes their study in the domain of geometric nonlinearity
This paper studies response of a leaf spring of parabolic shape, assumed to be made of highly elastic steel. Leaf
springs industries working with 65Si7 spring steel ,are using a very low factor of safety for weight reduction .To achieve
this, experimental testing is done to predict the spring rate, bending stress and deflection. . M.L. Aggarwal et al [10]
calculated fatigue strength of shot peened leaf springs from laboratory samples. The axial fatigue strength of EN45A spring
steel specimen is evaluated experimentally as a function of shot peening in the conditions used for full-scale leaf springs
testing in industries.
The main objective of this work is to perform finite element analysis of single leave leaf spring. experimental
results have been taken on a full scale static load testing machine, in which Single leave leaf spring is held under an axial
load at centre till maximum deflection. These The Experimental results will be compared with FEA results for validation.

MATERIAL AND METHODS

Material Properties and Design Parameters
The table-1 The chemical composition of the material.
Table 1: Chemical Composition of 65Si7
GRADE
C%
Si%
Mn %
P%
S%
Cr%

65Si7
0.51-0.62
0.15-0.35
0.65-0.95
.035 max
.035 max
0.65-0.95

Comparative Study of Single Leave Leaf Spring in CAE Tool and

Experimental Data of Leaf Springs in Automotive Vehicles

Table 2: Material Properties

Parameter
Material Selected-steel
Young Modulus, E
Poissons Ratio
BHN
Tensile strength Ultimate
Tensile strength Yield
Single leaves length
Spring stiffness
Normal Static loading
Density
Behavior

Value
65Si7
2.1*105 N/mm2
0.266
455-461
460 Mpa
250 Mpa
1608 mm
66.20 mm
40000 N
0.00000785Kg/mm3
Isotropic

Multi Leaf Spring Geometry and Boundary Conditions

The Geometry drawing of the single leave leaf spring is shown in the figure-1 below;

Figure 1: Geometry of Single Leave Leaf Spring

Loading Conditions
The static Loading condition of the single leave leaf spring involves the bottom side of two rollers of the freely
supported at the free end. Loading conditions involves applying a point load at the centre of the main leave leaf. As per
specifications the spring is drawn at inside length is reduce, therefore the load is applied in downward vertical direction to
achieve initial no load condition. The loading conditions are shown below in the Figure-2.

Figure 2: Experimental Condition

CAD Modeling & Finite Element Analysis
CAD modeling software is dedicated for the specialized job of 3D-modeling. The model of the single leave leaf
spring structures also includes many simple parts, which are difficult to make by any of other CAD modeling as well as

S. D. Rathod, D. S. Shah & S. A. Ban

Finite Element software. CAD modeling of the complete Single leave Leaf Spring structure is performed by using Solid
Works software. Solid Works is having special tools in generating surface design to construct typical surfaces, which are
later converted into solid models. Solid model of all parts of the structures are then assembled to make a complete
structure. The process of parts is very much analogous to general process of fabricating structures while real production.
The CAD model of single leave leaf spring used for FE Analysis during modeling drawing is shown in figure-1 and figure2.
Finite Element Analysis
A stress-deflection analysis is performed using finite element analysis (FEA). The complete procedure of analysis
has been done using ANSYS-14.0. To conduct finite element analysis, the general process of FEA is divided into three
main phases, preprocessor, solution, and postprocessor.
Preprocessor
The preprocessor is a program that processes the input data to produce the output that is used as input to the
subsequent phase (solution). Following are the input data that needs to be given to the preprocessor: i. Type of analysis ii.
Element type. iii. Real constants iv. Material properties v. Geometric model vi. Meshed model vii. Loading and boundary
conditions
Solution
Solution phase is completely automatic. The FEA software generates the element matrices, computes nodal values
and derivatives, and stores the result data in files. These files are further used by the subsequent phase (postprocessor) to
review and analyze the results through the graphic display and tabular listings.
Postprocessor
The output from the solution phase is in the numerical form and consists of nodal values of the field variable and
its derivatives. For example, in structural analysis, the output is nodal displacement and stress in the elements. The
postprocessor processes the result data and displays them in graphical form to check or analyze the result. The graphical
output gives the detailed information about the required result data. The single leave leaf spring with all boundary
conditions and material properties is imported in ANSYS-14.0, showing in figure-3, figure-4 and figure-5.
The material used for the single leave leaf spring for analysis is 65Si7, Which has approximately similar isotropic
behavior.

Figure 3: Meshing of Single Leave Leaf Spring

Comparative Study of Single Leave Leaf Spring in CAE Tool and

Experimental Data of Leaf Springs in Automotive Vehicles

Figure 4: No Separation Contact in Ansys-14.0

Figure 5: Boundary Condition in Ansys-14.0

RESULTS AND DISCUSSIONS

As the finite element analysis of single leave leaf spring is performed using ANSYS-14.0 detailed above, in which
all conditions are considered which were also considered for results taken by experimental testing. The single leave leaf
spring showing deflections under full & half rated loads are shown in figure-6 and figure-7, as well as in tabular form taken
from ANSYS-14.0.

Figure 6: Deformation at Full Load

S. D. Rathod, D. S. Shah & S. A. Ban

Figure 7: Deformation at Half Load

RESULTS COMPARISON & DISCUSSIONS

Table 3: Result Comparison at Full Load
Parameters
Normal Static Load
Deflection
Spring Rate
Bending Stress

Experiment Results
40000 N
17.000 mm
2352.94 N/mm
5967.18 N/mm2

FEA Results
40000 N
17.895 mm
2235.26 N/mm
5027.20 N /mm2

Variation
Nil
5.26%
5.00%
15.75%

As shown in the above table-3 deflection and the bending stress are compared for experimental and FEA results.
The experimental deflection value is 17 mm and the FEA value is 17.895 mm i.e. a negligible difference is detected. On
the other hand the bending stress is increased from 5967.18 N/mm2 to 5027.20 N/mm2 i.e. again a negligible difference is
detected.
Table 4: Result Comparison at Half Load
Parameters
Normal Static Load
Deflection
Spring Rate
Bending Stress

Experiment Results
20000 N
9.000 mm
2222.23 N/mm
2983.59 N/mm2

FEA Results
20000 N
8.9475 mm
2235.26 N/mm
2513.60 N /mm2

Variation
Nil
0.59%
0.58%
15.75%

As shown in the above table-4 the deflection and the bending stress with half rated load are compared for
experimental and FEA results. The experimental deflection value is 9.00 mm and the FEA value is 8.9475 mm i.e. a
negligible difference in Experimental and FEA value. On the other hand the bending stress is increased from
2

N/mm to 2513.60 N/mm i.e. the experimental value is higher than the FEA value safe.

Figure 8: Load-Deflection curve for FEA Results

2983.59

Comparative Study of Single Leave Leaf Spring in CAE Tool and

Experimental Data of Leaf Springs in Automotive Vehicles

CONCLUSIONS
Design and stress-deflection analysis of a multi leaf spring is carried out by finite element approach using CAE
tools (i.e Solid Works, ANSYS 14.0). When the leaf spring is fully loaded, a variation of 5.26 % in deflection is observed
between the experimental and FEA result, and same in case of half load, which validates the model and analysis. On the
other hand, bending stress in both the cases is also close to the experimental results. The maximum value of equivalent
stresses is below the Yield Stress of the material that the design is safe from failure.

REFERENCES
1.

Mouleeswaran Senthil kumar;sabapathy vijayarangan; (2007) Analytical and Experimental Studies on Fatigue
Life Prediction of Steel and Composite Multi-leaf Spring for Light Passenger Vehicles Using Life Data Analysis
Materials Science,Vol.-13,No. 2, p.p 141-146.

2.

Hawang, W., Han, K. S. (1986) Fatigue of Composites Fatigue Modulus Concept and Life Prediction Journal
of Composite Materials, vol-20, p.p. 154 165.

3.

H. A. Al-Qureshi (2001), Automobile leaf springs from composite materials, Journal of Material Processing
Technology, vol-118,p.p 58-61.

4.

J.J.Fuentes,H.J. Agulilar,J.A.Rodriguez,E.J. Herrera (2008) , Premature fracture in automobile leaf springs,

Engineering Failure Anlysis,vol-16,p.p 648-655.

5.

I. Rajendran, S. Vijayarangan, (2002) Design and Analysis of a Composite Leaf Spring Journal of Institute of
Engineers India, vol-82 pp. 180 187

6.

Gulur Siddaramanna Shiva shanker, Sambagam Vijayaragan (2006), Mono Composite Leaf Spring for Light
Weight Vehicle Design, End Joint Analysis and Testing Materials Science, vol-12, No-3,p.p 220-225.

7.

J.P. Hou; J.Y. Cherruault, I. Nairne, G. Jeronimidis, R.M. Mayer (2004), Evolution of the eye-end design of a
composite leaf springs for heavy axle loads, Composite Structures vol-28,p.p 351-358.

8.

Peiyong Qin, Glenn Dentel, and Mikhail Mesh (2002), Multi-Leaf Spring and Hotchkiss Suspension, ABAQUS
Users Conference.

9.

Muhammad Ashiqur Rahman*, Muhammad Tareq Siddiqui and Muhammad Arefin Kowser (2002), Design and
Non-Linear Analysis Of A Parabolic Leaf Spring, Journal of Mechanical Engineering vol-ME 37,p.p 47-51.

10. Aggarwal M.L; Agarwal V.P;Khan R.A (2006)A stress approach model for predicting fatigue life of shot peened
EN45A springs steel, International Journal of Fatigue,Elsevier publication,vol 28, p.p 1845-1853.