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Dynamic Analysis of Steel Leaf Spring

Conference Paper · November 2014

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 International Journal of Engineering Research & Technology (IJERT)
ISSN: 2278-0181
Vol. 3 Issue 11, November-2014

Dynamic Analysis of Steel Leaf Spring

Ashish P. Borhade Prof. Dr. J. T. Pattiwar

Department of Mechanical Engineering, Department of Mechanical Engineering,
Sandip Inst. of Engineering and Managament, Nashik NDMVPS’S KABGT COE, Nashik

Abstract— This work proposes modal analysis i.e. Natural II. LITERATURE REVIEW
Frequency Analysis of steel mono leaf spring. Natural frequency G Harinath Gowd and E Venugopal Goud has carried out
of selected leaf spring is determined experimentally by FFT static analysis of steel leaf spring & determined the maximum
analyzer. Finite Element Analysis will be carried out pay load of the vehicle experimentally and analystically[1].
considering existing conventional steel leaf spring of a light Pankaj saini and Ashish Goel designed and proposed a
commercial vehicle with a proper material properties and method of fabrication of composite mono leaf spring with
element types, to get Natural Frequency and Mode Shapes of the
better ride quality and carried out its static analysis using
mono leaf spring using Ansys Software. Comparison of the
natural frequency by FFT analyzer with FEA will also be done. Ansys 9.0[2]. [Link] Lakshmi1and I. Satyanarayana has
compared load carrying capacity and weight saving of
keywords—Modal anlysis, Natural frequency, Mode shapes, composite leaf spring with that of steel leaf spring[3]. Zoman
Solid works,Ansys workbench. Digamber, Jadhav Mahesh, P R Kharde and V R Kharde has
carried out static analysis of two conventional steel leaf spring
I. INTRODUCTION made up of SUP 10 & EN 45. Leaf spring was modelled in
Leaf spring is main component of automobile suspension CATIA V5R17 and analyzed using ANSYS 14.0. Analytical
system. It consists of a number of flat plates, which are results were compared with FEA results[4]. Shishay Amare
stacked together. The longest leaf, called the master leaf, is Gebremeskel has designed, simulated and analyzed
bend at both ends to form spring eyes. Through the eyes, composite leaf spring of three wheeler vehicle. He has
spring is attached to the body of the vehicle. prepared prototype of that leaf spring and carried out static
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One or two more full length leaves are provided between analysis[5]. He has considered static conditions only.
main or master leaf and other type of leaves known as
graduated leaves. These extra full length leaves are provided COMMENTS
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to support the transverse shear force, in addition to bending Review of papers concludes that dynamic analysis of steel
load.[11] leaf spring is not studied yet. So, The aim of present work is to
The leaves are given an initial curvature known as camber. carry out Dynamic Analysis (Modal Analysis) using ANSYS
This initial curvature is provided so that the leaves will tend to software and obtained results will be compared with the
straighten under the load. The leaves are held together by experimental results(FFT Analyser).
means of U-bolts and the central bolt or band shrunk around
them at centre. Rebound clips are located at intermediate III. PROBLEM DEFINITION
positions along the length of the spring. So that the graduated Objective of present work is to consider an existing
leaves share the rebound load with main or master leaf. The automobile leaf spring model and to carry out its dynamic
rebound clips also help to keep to keep leaves in alignment analysis (Modal Analysis).
and prevent lateral shifting of leaves during the operation. Modal Analysis is the basic dynamic analysis to calculate
the natural frequencies of the structures. Output of the modal
analysis is Natural Frequency and Mode Shapes. It helps to
understand the structural behavior in actual loading
conditions.
In present work Modal Analysis will be carried out using
Ansys Software and results will be compared with
experimental (FFT Analyzer) results and theoretical results.

IV. METHODOLOGY
[Link] of leaf spring 1) Experimental modal analysis using FFT analyzer
Suspension system prevents the road shocks from being Experimental set up is prepared to simulate actual
transmitted to the vehicle components also safeguard the working conditions. One end of steel leaf spring is
occupants, it preserves the stability of the vehicle in rolling, connected to fixed element which is welded to long metal
while in [Link] spring selected for this study is steel leaf strip, providing zero degrees of freedom. Another end of
spring of Armada vehicle. that spring is connected to shackle i.e flexible link which in
turn provides one directional displacent i.e. in X-direction
only. Experimental setup is shown in fig below.

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 International Journal of Engineering Research & Technology (IJERT)
ISSN: 2278-0181
Vol. 3 Issue 11, November-2014
Procedure for determination of natural frequencies is as
follows:
1)Select a pick value.
2)Check phase difference for that pick value, it is expected
to be 180°. If this condition is satisfied then go for 3 rd
step and if not then select next pick and follow steps 1
and 2.
[Link] arrangement 3)Check coherence for that corresponding pick, it is
expected to be one ideally(0.75 to 1 can also be
choosen). If this condition is satisfied then
corresponding pick will give first natural frequency and
if not then select next pick and follow steps 1,2 and 3
again. In this way we can get First, second, third,…..etc.
natural frequencies by using FFT analyzer.
Results(First six natural frequencies) obtained by this
experiment are given below. [10]

[Link] Natural Frequencies(Hz)

1 225
2 525
3 1075
[Link] analysis on FFT analyzer
4 1300
Experimental procedure for modal analysis on FFT 5 1575
analyzer: 6 2475
1)Start the FFT analyzer. [Link] frequencies obtained on FFT
2)Go to Run-up mode-set-New set(Rename)-OK.
3)Set the ranges of force amplitude, frequency and scale 2)Modal analysis by FEA(Ansys).
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for graphs. Modal analysis in ansys has been carried out with
4)A force of very small amplitude is applied on a steel leaf following steps:
spring by a hammer which is provided with FFT 1. Material testing using spectrometer to determine
analyzer and corresponding results(Natural frequencies) material of selected leaf spring. According to
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are obtained on FFT analyzer. These results are shown material configuration obtained on spectrometer,
below: name of the material is determined.
2. According to the material, material properties are
selected from design data book. [13]
3. Dimensions of selected leaf spring are obtained
and its model is drawn in Solid works.
4. That model is imported in Ansys.
5. Material properties of that material are entered in
the Ansys.
6. Boundary conditions are given i.e. one end is fixed
having zero degrees of freedom and another end is
having only one degree of freedom i.e. in
X-direction.
7. Natural frequencies and mode shapes are obtained.
8. Experimental results are compared with FEA
results.
Above steps are explained in detail in further sections:

1)Material testing using spectrometer to determine

[Link] on FFT analyzer material of selected leaf spring:
Material of selected leaf spring is determined by
This graph shows magnitude of input force, phase spectrometer. Experimental arrangement is shown
difference and coherence on Y-axis and natural frequency below.
on X-axis.

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 International Journal of Engineering Research & Technology (IJERT)
ISSN: 2278-0181
Vol. 3 Issue 11, November-2014
Steps of modeling of leaf spring in solid works with
above dimensions:
i. Draw a rectangle of dimensions 875*130.
ii. Draw circles at both top most corners of dia 35 mm.
iii. Draw a centerline at 875/2 distance.
[Link] a 3 point arc passing through two topmost corner
of rectangle and third point as a intersection of
centerline with bottom side of rectangle.
[Link] testing on Spectrometer
v. Make it tangent with both the circle drawn at the
Results obtained by this testing are shown in the table below. upper side of rectangle.
[Link] the extra part of the circle.
[Link] the thickness by offset command by 5 mm.
Observed Specified Value [Link] this sketch by 62 mm to provide required
Sr. Readings of
Elements Remark width.
No.
% 55Si2Mn90 4)Import this model in Ansys workbench:
1 C 0.58 0.5-0.6 5)Enter the material properties I the Ansys which are
Material obtained from design data book.
2 Mn 0.97 0.8-1
3 Si 1.68 1.5-2 Confirms to 6)Apply boundary conditions:
4 P 0.04 --- steel One end of the leaf spring is fix [Link] degree of
5 S --- 55Si2Mn90 freedom and other end connected to shackle is having
0.05
6 Cr --- Grade
one degree of freedom i.e. in X-direction.
0.1
7 Mo 0.03 ---

[Link] configurations obtained by testing of leaf

spring on Spectrometer

Where,C-Carbon, Mn-Mangenese, Si-Silicon, P-

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Phosphorous, S-Sulphur,Cr-Chromium,Mo-Molybdenum.

Hence, material of selected leaf spring is Silicon Magnesium

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Steel.
2)Material of selected leaf spring is of grade 55Si2Mn90.
[Link] Mangesium steel. From P.S.G. Design Data
Book[9] Material properties of Silicon Magnesium Steel
are selected which are as follows:
Youngs modulus=2.1*e5 N/mm2
[Link] conditions for FEA testing of leaf spring
Density=7.860*e-6 kg/mm3
Poissions ratio= 0.3 7) Natural frequencies and mode shapes are obtained after
Tensile strength=1962 N/mm2 FEA analysis in Ansys are as follows[12].
3) Dimensions of selected leaf spring are obtained and its
model is drawn in Solid works in following steps. [Link] Natural Frequencies(Hz)
Dimensions: 1 207.75
Span= 875 mm(center to center), 2 517.3
Camber= 130 mm, 3 1158.1
Width at end = 62 mm, 4 1277.8
Width at center = 62 mm,
5 1589.
Thickness = 5mm,
6 2455.5
Inner dia = 35 mm,
Outer dia = 45 mm.
[Link] frequencies obtained by FEA analysis of leaf
spring

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 International Journal of Engineering Research & Technology (IJERT)
ISSN: 2278-0181
Vol. 3 Issue 11, November-2014
Mode shapes are given below:

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[Link] shapes obtained for first six natural frequencies

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(This work is licensed under a Creative Commons Attribution 4.0 International License.)
 International Journal of Engineering Research & Technology (IJERT)
ISSN: 2278-0181
Vol. 3 Issue 11, November-2014
VI. CONCLUSION
V. RESULTS AND DISCUSSION Results obtained by experimental modal analysis and by FEA
Natural frequencies of steel leaf spring is determined by analysis are nearly same. So, one can say that these are quite
Experimental modal analysis and by FEA analysis and the correct values of frequencies of selected steel leaf spring. So,
results are comparable. These results are shown in the table if material of this steel leaf spring is changed keeping its
below. dimensions same as initial dimensions and if the change in
Natural Frequency(Hz) Natural Frequency(Hz) natural frequencies of that spring is studied with respect to
[Link]
Experimental FEA change in material of that spring, this study will be useful for
1 225 207.75 material optimization of leaf spring.
2 525 517.3
3 1075 1158.1 REFERENCES
[1] G Harinath Gowd and E Venugopal Goud, “Static
4 1300 1277.8
analysis of leaf spring” International Journal of
5 1575 1589 Engineering Science and Technology (IJEST), Aug
6 2475 2455.5 2012
[2] Pankaj Saini, Ashish Goel & Dushyant Kumar,
[Link] of Experimental and FEA results “Design and analysis of composite Leaf spring for light
vehicles”. International Journal of Innovative Research
in Science, Engineering and Technology Vol. 2, Issue 5,
From above table, it is seen that natural frequencies of steel May 2013
leaf spring obtained experimentally are quite comparable with [3] [Link] Lakshmi1 & I. Satyanarayana, “Static and
the natural frequencies obtained by FEA analysis. Hence we dynamic analysis on composite leaf spring in heavy vehicle”.
can say that these frequencies are closer to the actual values of Dec-2012.
frequencies of that particular steel leaf spring. [4] Zoman Digamber B, Jadhav Mahesh V, R
R Kharde & Y R Kharde, “FEA Analysis of
master leaf spring”
[5] Shishay Amare Gebremeskel, “Design,simulation and
prototyping of single composite leaf spring for light wt
vehicle”.Feb 2012.
[6] Zhi’an Yang and et al “Cyclic Creep and Cyclic
Deformation of High-Strength Spring Steels and the
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Evaluation of the Sag Effect:Part I. Cyclic Plastic
Deformation Behavior” Material and Material
Transaction A Vol 32A, July 2001—1697
C.K. Clarke and G.E. Borowski “Evaluation of Leaf
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[7]
Spring Failure” ASM International, Journal of Failure
AnalysisandPrevention,Vol5(6)Pg. No.(54-63).
.[8] [Link] & S. Vijayarangan(2002) “A parametric
study on free vibration of Leaf spring.
[9] [Link] data book, page-1.15 & 1.17.
[10] Practical Machinery Vibration analysis and Predictive
[Link]-4, Signal processing
applications and representations.
[11] A textbook of Machine Design by R.S Khurmi.
[12] Ansys Fluent in Ansys workbench Users guide,
ansysinfo@[Link]

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