design and analysis of leaf spring suspension of mahindra

International Journal of Scientific Research and Engineering Development-– Volume 4 Issue 4, July- Aug 2021

Available at www.ijsred.com

ISSN : 2581-7175 ©IJSRED:All Rights are Reserved 028

Design and Analysis of Leaf Spring Suspension of Mahindra

Commander

Mayuresh Kulkarni *,Prathamesh Killedar **,Pravin Gosavi*** *Department of mechanical engineering, KIT’s college of engineering (Autonomous institute), Kolhapur

Email: [email protected]

** Department of mechanical engineering, KIT’s college of engineering (Autonomous institute), Kolhapur

Email:[email protected]

***Department of mechanical engineering, KIT’s college of engineering (Autonomous institute), Kolhapur

Email :[email protected]

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Abstract: This paper describes the design and analysis of leaf spring of steel material and composite material.

The objective of these paper is compare all composite materials and their load carrying

capacity ,strength ,weight savings of composite leaf spring over the steel leaf spring. The leaf spring

designed for MAHINDRA COMMANDOR 650di for weight 2150Kg.The CAD modeling of leaf spring

has been done on Solidworks and analysis is done on ansyssoftware.Objective is to find the equivalent

stresses and deformation, Equivalent strain of spring under static load conditions. The version of leaf

spring created in Solidworks in different four materials steel, carbon Fiber, Epoxy Carbon, E-glass. The

load action on spring considered as 537.5N.After comparative study we concluded that E-glass is more

suitable material than any other materials studied.

Keywords —leaf spring, composite material , conventional material, Mahindra commander

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I. INTRODUCTION

Multi-leaf spring are widely used for the suspension

of cars , trucks and railways wagons. It consist of a

series of flat plates in semi-elliptical shape .The flat

plates are called leaves of spring. The leaves are

held together by use of two U bolts and center clip.

Rebound clip provided to keep leavesin position or

in alignment and prevent lateral shifting during

operation. There are three types of leaves in leaf

spring. Master leaf ,full length leaves and graduated

level leaves. The master leave is called as longest

leaf, this leaf prevent the spring from both

end.Multi-leaf springs are provided with one or two

extra full length leaves in addition to master

leaf.And also have graduated length leaves are

forms one another group they treated as triangular

plate.

In this paper we try to design and analysis of leaf

spring and apply two materials one is steel and

another is glass jute which is composite

material .Now days automobile industries are

finding some innovation and some change in there

materials for the drawback they were faced with

the material. So by considering there researches and

requirements in the material used for leaf spring.

We are compared different materials one is

conventional and another is composite material .

what properties they having and which material is

better in future for suspension systems.

RESEARCH ARTICLE OPEN ACCESS

International Journal of Scientific Research and Engineering Development

©IJSRED: All Rights are Reserved

Multi leaf spring diagram -:

II. LITERATURE REVIEW

1) M. Arther Clive from department of mechanical

engineering, SVS college of

engineering ,Coimbatore, Tamilnadu

compared deflection, equivalent stress, equivalent

elastic strain of carbon fiber, carbon epoxy, E

epoxy over conventional leaf springs in AutoCAD

2012. Mesh is created in Hypermesh software. They

done analysis of model in ANSYS 9.0. After

analysis they concluded that leaf spring of E

shows high deformation.

2)Sandip R Mundale, Prof.D.B.Pawar,

Prof.D.J.Verma presented a paper in which they

designed lead spring of Mahindra Commander in

CATIA software. They studied comparison

between steel, glass epoxy, carbon epoxy under

static load of 5375N. Analysis is done on ANSYS

software The deformation, stress and strain is

analyzed they concluded that composite material

used for leaf spring can reduce weight and stress.

3)G HarinathGowd from Sri S

Engineering College and E VenugopalGound from

Pullareddy engineering college presented work

presented work that attempts to analyze the safe

load of leaf spring from that comfortable speed with

safe drive can be decided. They choose TATA

light commercial vehicle for study. Finite Element

Analysis is done on ANSYS software. From results

they concluded max stress for given specifications

of leaf spring. Max stress is developed at inner side

of eye section

An easy way to comply with the conferen

paper formatting requirements is to use th

document as a template and simply type your text

into it.

Research and Engineering Development-– Volume 4 Issue 4,



1) M. Arther Clive from department of mechanical

engineering, SVS college of

engineering ,Coimbatore, Tamilnadu ,India

compared deflection, equivalent stress, equivalent

elastic strain of carbon fiber, carbon epoxy, E-glass

epoxy over conventional leaf springs in AutoCAD

2012. Mesh is created in Hypermesh software. They

done analysis of model in ANSYS 9.0. After

alysis they concluded that leaf spring of E-glass

2)Sandip R Mundale, Prof.D.B.Pawar,

Prof.D.J.Verma presented a paper in which they

designed lead spring of Mahindra Commander in

CATIA software. They studied comparison

l, glass epoxy, carbon epoxy under

static load of 5375N. Analysis is done on ANSYS

software The deformation, stress and strain is

analyzed they concluded that composite material

used for leaf spring can reduce weight and stress.

3)G HarinathGowd from Sri Shadevaraya

Engineering College and E VenugopalGound from

Pullareddy engineering college presented work

presented work that attempts to analyze the safe

load of leaf spring from that comfortable speed with

safe drive can be decided. They choose TATA-407

ht commercial vehicle for study. Finite Element

Analysis is done on ANSYS software. From results

they concluded max stress for given specifications

of leaf spring. Max stress is developed at inner side

An easy way to comply with the conference

paper formatting requirements is to use this

and simply type your text

DESIGN METHODOLOGY -

Leaf springs are also much studier as compared to

coil spring . They are capable of handling much

higher loads with less deflection than other coils of

the suspension which are used .Trucks with leaf

springs are also easier to raise or lower loads.

The solution for the problem is problems performed

in two stages-:

1)Design and analysis of leaf spring by applying

conventional steel material on spring .

2) Design and analysis of leaf spring by applying

composite materials on spring .

3) compare all analysis of the material which

used for leaf spring

Leaf spring of suspension system of MAHINDRA

COMMANDAR 650DI is designed by using

SOLIDWORKS 2019 with respective dimensions

of the vehicle. After that finaite element analysis is

done by using ANSYS 2021 R1.

Specifications for design of leaf spring of

MAHINDRA COMANDAR 650Di

For design and analysis of leaf spring all the

specification are consider of MAHINDRA

COMANDAR 650DiJeep . The specifications of

leaf spring are given in following table

Sr no Parameter name

1 Material

2 Leaf span (2L)

3 No of full length

leaves

4 No of graduated

leafs

5 Total no of

leaves

4 Width

7 Thickness

8 Young’s

modulus of leaf

spring

9 Ineffective

length

Volume 4 Issue 4, July- Aug 2021

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Page 1029

-:

Leaf springs are also much studier as compared to

coil spring . They are capable of handling much

ion than other coils of

the suspension which are used .Trucks with leaf

springs are also easier to raise or lower loads.

olution for the problem is problems performed

Design and analysis of leaf spring by applying

conventional steel material on spring .

2) Design and analysis of leaf spring by applying

all analysis of the material which

Leaf spring of suspension system of MAHINDRA

COMMANDAR 650DI is designed by using

SOLIDWORKS 2019 with respective dimensions

of the vehicle. After that finaite element analysis is

YS 2021 R1.

Specifications for design of leaf spring of

MAHINDRA COMANDAR 650Di -:

For design and analysis of leaf spring all the

specification are consider of MAHINDRA

COMANDAR 650DiJeep . The specifications of

leaf spring are given in following table -:

Value

Steel EN45A

1120mm

No of full length 2

No of graduated 8

10

50mm

6mm

210000Mpa

100mm



MATERIAL PROPERTIES:

Steel EN45 is conventionally used for leaf spring of

light weight vehicles. Steel EN45 has chemical

composition o.64% Carbon,0.4% Chromium,2.2%

Silicon,1% Manganese, 0.4%

Nickel,0.1%Molybdenum,0.04% Sulfur,0.035

Phosphorous which is generally used to

manufacture swards and knives.

steel EN45A

Young’s modulus[E] 210GPa

Ultimate tensile strength 1272 mPa

Poisson’s ratio 0.266

Yield strength 1158 mPa

Carbon Fiber:

Carbon Fibers are mostly composed of carbon

atoms and fibers having 5-10 micro meters in

diameter. It has high stiffness, high tensile strength,

high chemical resistance. It is mostly used in

aerospace industry and military applications.

Properties Value

Young’s modulus[E] 500GPa

Ultimate tensile strength 4000 mPa

Poisson’s ratio 0.17

Yield strength 2500 mPa

Epoxy Carbon:

Composite materials are made up of combination of

reinforced fiber with resin matrix. Due to extremely

strong carbon-carbon molecular bond they get high

strength

Properties Value

Young’s modulus[E] 110-120e+3 N/mm^2

Ultimate tensile strength 228e+3 MPa

Poisson’s ratio 0.27-0.30

Yield strength 1034 MPa

E-glass:

E glass is low alkali glass having composition of

Silicon Dioxide (52%-56%) , Calcium Oxide (16%

25%), Aluminum Oxide(12%-16%), Boron

Oxide(5%-10%), Sodium Oxide(2%) , Magnesium

Oxide(5%), Iron Oxide(0.05%-0.4%), Titanium

Oxide(0.8%), Fluorides(1%).It is mostly used for




Steel EN45 is conventionally used for leaf spring of

light weight vehicles. Steel EN45 has chemical

composition o.64% Carbon,0.4% Chromium,2.2%

Nickel,0.1%Molybdenum,0.04% Sulfur,0.035

h is generally used to

EN45A

210GPa

1272 mPa

0.266

1158 mPa

Carbon Fibers are mostly composed of carbon

10 micro meters in

diameter. It has high stiffness, high tensile strength,

high chemical resistance. It is mostly used in

aerospace industry and military applications.

Value

500GPa

4000 mPa

2500 mPa

Composite materials are made up of combination of

reinforced fiber with resin matrix. Due to extremely

ar bond they get high

Value

120e+3 N/mm^2

228e+3 MPa

0.30

1034 MPa

E glass is low alkali glass having composition of

56%) , Calcium Oxide (16%-

16%), Boron

10%), Sodium Oxide(2%) , Magnesium

0.4%), Titanium

ostly used for

production of composite panels, surfboards, storage

tanks

Properties

Young’s modulus[E]

tensile strength

Poisson’s ratio

Yield strength

Dynamic specifications of Mahindra

COMMANDER 650 di Jeep:

Specification

Gross Vehicle weight

Wheel Base

Engine

Type Four stroke over square four

Wt of Engine

Wheel, Rim, Tyre

Track width

Turning Circle Radius

ANALYSIS OF LEAF Steel

First material is selected for analysis is

conventional structural steel. Results are given in

Following table.

Parameter:- Total

Deformation

Maximum

Minimum

Average 6.6978e

Parameter:- Equivalent

stress

Maximum

Minimum

Average


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production of composite panels, surfboards, storage

Value

76GPa

3400 MPa

0.30

3500

Dynamic specifications of Mahindra

COMMANDER 650 di Jeep:

Value

2150 kg

2680 mm

MD13000

Four stroke over square four

cylinder incline

275Kg

5 inches

3 mm

60mm

ANALYSIS OF LEAF SPRING:

First material is selected for analysis is

conventional structural steel. Results are given in

value

0.11442 mm

0 mm

6.6978e-0.002mm

Value

55.248 MPa

5.357e-007 MPa

5.316 MPa



Parameter:-Equivalent

Elastic Strain

Value

Maximum 2.7682e-004 mm/mm

Minimum 3.1118e-012 mm/mm

Average 2.6885e-005 mm/mm

Carbon Fiber:-

Parameter:- Total

Deformation

Value

Maximum 2.188e-007 mm

Minimum 0 mm

Average 1.4587e-007 mm


stress

Value

Maximum 78.026MPa

Minimum 2.6311e-10MPa

Average 5.7552MPa




Value

004 mm/mm

012 mm/mm

005 mm/mm

alue

007 mm

0 mm

007 mm

Value

78.026MPa

10MPa

5.7552MPa


Elastic Strain

Maximum 2.185e

Minimum 1.7539e

Average 1.3737e

Epoxy Carbon:

Parameter:- Total

Deformation

Maximum 3.2554e

Minimum

Average 2.1312e


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Value

2.185e-003 mm/mm

1.7539e-014 mm/mm

1.3737e-004 mm/mm

Epoxy Carbon:-

value

3.2554e-007 mm

0 mm

2.1312e-007 mm




stress

Value

Maximum 67.698MPa

Minimum 3.9935e-9MPa

Average 5.6425MPa


Elastic Strain

Value

Maximum 2.9513e-

mm/mm

Minimum 2.8834e-

mm/mm

Average 1.7996-004

mm/mm




Value

67.698MPa

9MPa

5.6425MPa

Value

-003

mm/mm

-013

mm/mm

004

mm/mm

E-Glass:-

Parameter:- Total

Deformation

Maximum 3.1341e

Minimum

Average 1.8359e

Parameter:-

Equivalent

stress

Value

Maximum 54.962MPa

Minimum 0.23611e

Average 5.3168MPa


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value

3.1341e-007 mm

0 mm

1.8359e-007 mm

Value

54.962MPa

0.23611e-6MPa

5.3168MPa




Elastic Strain

Value

Maximum 7.5361e-004 mm/mm

Minimum 3.2349e-012 mm/mm

Average 7.3688e-005 mm/mm

CONCLUSION : Composite materials have high strength

ratio. They more stronger and stiffer than

conventional materials. Hence due to their

advantages like cost reduction, weight reduction

and recyclability composite materials are important

part of modern automotive industry. After

Analytical and Comparative study between total

deformation, equivalent stress, equivalent strain of

conventional steel, Carbon fiber, Epoxy carbon, E

glass it can be concluded that E-glass has better

deformation than other materials. Equivalent stress

of E-glass is also reduced than conventional

material.

REFERENCES [1] G. Harinath, and E. VenugopalGoud. "Static analysis of leaf spring."

International Journal of Engineering Science and Technology 4.8 (2012): 3794-3803

https://www.ijeat.org/wp-

content/uploads/papers/v2i3/C1061022313.pdf [2] Barnabas, J. Kingston. "Optimization of Leaf Spring parameters using

Taguchi’s DoE." (2020)

https://www.irjet.net/archives/V5/i6/IRJET-V5I6584.pdf

[3] Sandip R. Mundale, Prof. D.B.Pawar, Prof.D.J.Verma.“Design and

Analysis of Composite Leaf Spring using composite materi

weight vehicle.” International Journal of Advance Engineering and

Research Development. volume 4,Issue 12, December 2017.

https://issuu.com/editorijaerd/docs/design_and_analysis_of_composite

_le




Value

004 mm/mm

012 mm/mm

005 mm/mm

Composite materials have high strength-to-weight

ratio. They more stronger and stiffer than

conventional materials. Hence due to their

advantages like cost reduction, weight reduction

and recyclability composite materials are important

otive industry. After

Analytical and Comparative study between total

deformation, equivalent stress, equivalent strain of

conventional steel, Carbon fiber, Epoxy carbon, E-

glass has better

Equivalent stress

glass is also reduced than conventional

G. Harinath, and E. VenugopalGoud. "Static analysis of leaf spring."

International Journal of Engineering Science and Technology 4.8

Barnabas, J. Kingston. "Optimization of Leaf Spring parameters using

V5I6584.pdf

Sandip R. Mundale, Prof. D.B.Pawar, Prof.D.J.Verma.“Design and

Analysis of Composite Leaf Spring using composite material for light

weight vehicle.” International Journal of Advance Engineering and

Research Development. volume 4,Issue 12, December 2017.

https://issuu.com/editorijaerd/docs/design_and_analysis_of_composite


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