Design, Analysis and Optimization of a Lightweight Vehicle's Leaf Springs

Abstract

In recent years, the automobile industry has primarily concentrated on reducing weight and improving ride quality. Because composite materials have a high strength-to-weight ratio, strong corrosion-resistance, and tailorable qualities, Steel leaf springs are being phased out in favour of composite leaf springs in the automotive industry. Three strategies have been investigated to reduce vehicle weight: rationalizing the body structure, using lightweight materials for parts, and reducing vehicle size. This study describes the static and dynamic analysis of steel 55Si2Mn90 parabolic leaf springs as well as composite parabolic leaf springs consisting of E Glass fibre, Carbon fibre, and Kevlar fibre. The goal of this study is to examine the load-carrying capability, stiffness, and weight reduction of composite and steel leaf springs. Dimensions of an existing steel 55Si2Mn90 parabolic leaf spring and a light commercial vehicle's composite parabolic leaf spring are taken. In terms of weight and stress developed, a comparison was made between composite and steel leaf springs. The Kevlar fiber leaf spring, after optimization, is 45.67% lower in weight than other materials and has superior riding quality than a typical steel spring with equal design criteria.