Volume 9, Issue 9, September – 2024 International Journal of Innovative Science and Research Technology

ISSN No:-2456-2165 https://doi.org/10.38124/ijisrt/IJISRT24SEP1078

Finite Element Analysis of Leaf Spring Fabricated

Via Fused Deposition Modeling (FDM)
Pratik Balkrishna Patil1; N. D. Patil2; P. P. Awate3
2,3
Professor, Department of Mechanical Engineering
Padmabhooshan Vasantraodada Patil Institute of Technology. Budhgaon-416304, Maharashtra, India

Abstract:- An introduction to fused deposition The leaf spring's role in automobile applications is
modeling, or 3D printing technology, will be given in multifaceted, providing suspension, shock absorption, and
this chapter. The basic idea of additive manufacturing support for lateral loads, brake, and driving torque. Unlike
and its underlying scientific theory will be presented at helical springs, leaf springs can be guided along a defined
the outset of this chapter as a novel and emerging path during deflection, serving both as structural
industrial technology. The parameters used to predict components and energy absorbers. Weight reduction in leaf
the melt deposition of polymers and their basic springs, achieved through composite materials like FRP,
interactions with the structural component qualities will improves vehicle ride quality without compromising load
also be covered in this chapter. The chapter will provide capacity or stiffness. In practical testing, determining load
a brief description of the quality features of FDM rate and fatigue life is time-intensive, requiring
products concerning the process parameters. The approximately 2-3 days for 100,000 cycles of fatigue life
additive manufacturing process will involve layering assessment using a full-scale testing machine. Factors
material to produce three-dimensional (3D) parts using affecting fatigue life, such as material treatment, loading
a class of manufacturing technologies known as additive conditions, surface characteristics, size, and environment,
manufacturing (AM). This substance will include must be carefully considered.
composite, metal, polymer, or concrete materials. A
manufacturing process will need to have the following Engineers face the challenge of developing reliable
three main elements to be designated as an AM and timely methods for fatigue life assessment. Although
technique: making visual 3D models with computers analytical and simulation methods provide approximate
and computer-aided design (CAD), utilizing a variety of results, they still need to be validated.
CAD tools such as AutoCAD, SolidWorks, CATIA, and
others. Some of these programs will be either closed- A. Conventional Methods:
source or open-source. For additive manufacturing to
be successful, an engineer or artist working with several  Hand layup,
computers will need to be proficient in using multiple  Extrusion,
operating systems. With these CAD tools and user  Vacuum bagging,
experiences, it will be possible to produce a variety of  Resin transfer molding,
complex 3D product models. The amount of material a  Hot Isostatic resin pressure molding.
3D printer will take and the time it will require will be
important factors influencing the additive B. Additive Manufacturing Methods:
manufacturing process.
 Selective laser sintering,
Keywords:- Leaf Spring, Composite Material, Automobile
 Multijet modeling.
Suspension System, Finite Element Analysis.
 3D printing,
 Fused deposition modeling.
I. INTRODUCTION

Automotive leaf spring suspension system has great

potential for weight reduction, it is 10 % to 20% build up
%. From zero weight, the introduction of composite
materials can reduce weight without compromising load
capacity or stiffness. Weight reduction is important for
energy savings in vehicle design and directly affects fuel
consumption. Composite materials, such as fiber-reinforced
plastics (FRP), provide better strength-to-weight ratios and
more elastic strain energy storage than steel, enhancing
fatigue resistance and durability.

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Volume 9, Issue 9, September – 2024 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165 https://doi.org/10.38124/ijisrt/IJISRT24SEP1078

 FDM Modeling Process: -

Fig 1: Factors Affecting the Modeling of Fused Deposition

II. PROBLEM STATEMENT

 The setup sequence is complete with UTM.
We list a few of the issues that typically arise while  Selection of measurement point.
using leaf springs. Several issues with the typical composite  Deflection measurement under defined loading
leaf spring have been noted, and they are as follows: conditions.
 Comparison of load/deflection values obtained from
 Maximum deformation: - Maximum deformation FEM analysis with values obtained from testing and
change in shape that a material or structure experiences UTM for carbon fiber plate specimens
under applied loads or conditions.  Comparison of load/deflection values obtained from
 Low strength: - Low strength indicates that a material or FEM analysis for fdm plate and steel plate.
structure lacks the necessary capacity to withstand
applied forces or loads without deformation or failure. III. METHODOLOGY
 High weight: - Steel leaf springs are heavy, as compared
to the composite leaf springs adding significant weight  The available literature has been reviewed to study the
to the vehicle. This affects fuel efficiency and handling. current state of the art in the design and construction of
 Continuous operation of the mini loader vehicle reduces composite leaf springs.
the spring's comfort level.  Design of composite leaf springs and selection of
 Leaf springs often break and weaken near the shackle materials for additional construction based on different
end and the center. conditions.
 The conventional steel leaf spring is heavy, reducing  Analysis of leaf springs will be done using finite
fuel efficiency. element analysis software such as ANSYS.
 The design of composite leaf springs with materials
 Objectives: such as E-glass/epoxy and plastic is suitable for
The objective of this review paper is to perform a fabrication using additive manufacturing techniques.
finite element analysis of the FDM sheet spring  Results will be validated by manufacturing and testing
and its experimental validation. composite sheet springs for defined designs
and composites.
The following steps will be taken to achieve the
objective of this work.  Selection of Composite Material: -
To ensure a good suspension system, the ability to
 Experimental Validation: absorb and store energy is important. However, the issue of
An example of an FDM leaf will be made for heavy springs remains. This problem can be solved by
UTM testing based on the leaf spring dimensions of the using composite materials instead of steel springs.
Maruti 800 car. FEM results will be validated using
UTM. The following steps are followed for test validation.

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Volume 9, Issue 9, September – 2024 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165 https://doi.org/10.38124/ijisrt/IJISRT24SEP1078

Studies have shown that there are many better E-glass fiber, a high-quality reinforced fiber, meets
options in terms of power and cost. the requirements for mechanical properties and is widely
used in today's systems.

Therefore, the selected material is E-glass/epoxy.

IV. MATERIAL AND THEIR PROPERTIES

Table 1: General Design Parameters of Composite Leaf Spring

Properties Value Unit
Density (Kg/m3) 7850 (Kg/m
Tensile Strength 650-880 Mpa
Young's Modulus (MPa) 200000-200000 Mpa
Elongation 8-25 %
Fatigue 275-275 Mpa
Yield strength 350-550 Mpa

Table 2: The Mechanical Properties of the E-Glass/Epoxy.

Properties Value
Tensile modulus along X-direction (Ex),Mpa 34000
Tensile modulus along Y-direction (Ey),Mpa 6530
Tensile modulus along Z-direction (Ez),Mpa 6530
Tensile strength of the material,Mpa 900
Compressive strength of the material,Mpa 450
Shear modulus along XY-direction (Gxy),Mpa 2433
Shear modulus along YZ-direction (Gyz),Mpa 1698
Shear modulus along ZX-direction (Gzx),Mpa 2433
Poisson's ratio along XY-direction (NUxy) 0.217
Poisson's ratio along YZ-direction (NUyz) 0.366
Poisson's ratio along ZX-direction (NUzx) 0.217
Mass density of the material 2.6.106
Flexural modulus of the material, Mpa 40000
Flexural strength of the material, Mpa 1200

 Procedure to be Followed: FEA is used for structural, thermal, and fluid analysis,
but it can also be used for other types of simulations.
 Choose the Vehicle (Maruti800).
 Measuring the Parameters of the current leaf spring. V. CONCLUSIONS
 Analyze various leaf designs using ANSYS 14.
 Fabricate the composite leaf spring.  Through computer analysis, the maximum deflection in
 Test different leaf configurations using a fatigue testing the horizontal and vertical direction and the von Mises
machine. stress will be determined using a vertical load of up to
150 kg in increments of 50 kg, in the middle of the
 Components to Be Design: - hundred fdm spring called by Maruti 800 cars.
producer. These deflections and von Mises stresses are
 Master leaf favorable compared to steel plate analysis observed
 Graduated leaf with a 9% acceptable variation.
 When compared to the current standard metal spring,
 FEA (Finite Element Analysis): the weight of the composite leaf spring ought to be
FEA is a computer technique that models lower. A composite variant constructed of E-
real systems. It divides the structure into glass/epoxy composites will take its place.
smaller elements, assigns equations to  The stresses and strains resulting from a composite leaf
each, and solves them simultaneously to predict the spring should be less than the stresses of a conventional
overall behavior of the system. This method is particularly steel spring.
useful for complex geometries, loads, and materials
where accurate analytical solutions are difficult to obtain.

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Volume 9, Issue 9, September – 2024 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165 https://doi.org/10.38124/ijisrt/IJISRT24SEP1078

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