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A methodological study of leaf spring by material comparison and Taguchi’s DOE

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Abstract

The automotive sector showed a great interest in the composite leaf spring as a substitute for steel springs due to high strength-to-weight ratios. The better mechanical properties, lower density, and manufacturing feasibility of composites in aviation, marine, and automotive industries also have a broad acceptance. The aim is to evaluate the effect of the leaf spring when the composite is applied as a substitution. This study observed static conduct for a composite leaf spring in comparison to that of a steel leaf spring concerning deformation, load-bearing, stresses, and weight savings. Deformation and stresses were taken as design constraints. The specification and dimensional were optimized using Taguchi’s technique. To study the static behaviour, Finite Element Analysis (FEA) is done using ANSYS workbench 19.2. To simulate operating conditions by modelling the Leaf spring in the 3-D modelling software SOLIDWORKS. To validate the results of the software, the results were compared to the numerical method. For the Design of Experiments (DOE), Minitab software was used. Moreover, the outcome of the study represents the performance of composite material in leaf spring along with the design optimization. The composite material was found to give better performance over conventional material. Furthermore, the stress-induced in it was minimum i.e., 448.32 MPa, 491.32 MPa, 488.32 MPa in carbon epoxy, S glass epoxy, and E glass epoxy compared to 496.98 MPa in plain carbon steel and the deformation was optimum. Also, the weight of the composite material is less i.e., 3.884 kg, 4.338 kg, 2.506 kg in S glass epoxy, E glass epoxy, and Carbon epoxy compared to 12.217 kg in plain carbon steel.

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Authors and Affiliations

  1. Mechanical Engineering Department, R. N. G. Patel Institute of Technology, Bardoli, Surat, Gujarat, 394620, India

    Sagarsingh Kushwah, Shreyashkumar Parekh, Harsh Mistry, Meet Bhatt & V. K. Joshi

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  1. Sagarsingh Kushwah
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Correspondence to Sagarsingh Kushwah.

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Kushwah, S., Parekh, S., Mistry, H. et al. A methodological study of leaf spring by material comparison and Taguchi’s DOE. Int J Interact Des Manuf 16, 239–252 (2022). https://doi.org/10.1007/s12008-021-00831-8

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