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Evaluating the Reliability of Glass-Braid-Reinforced Polymer Composite Coil Spring for Automotive Suspension Development Using Finite Element Method and Empirical Tests

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Abstract

This study conducted a comprehensive assessment of the reliability of automobile glass-braid-reinforced polymer (GBRP) composite coil springs fabricated using a braiding technique. The evaluations encompassed durability, plastic deformation, and resistance to chipping, adhering to the industrial standards established for steel springs within the automobile industry. In addition, a method to evaluate the void distribution and impregnation rate is proposed to quantitatively evaluate the quality of the composite fabrication. A method for testing part of manufactured springs was developed using finite element analysis, and the validity of this testing method was confirmed through empirical testing. Upon completing the durability and plastic deformation examinations, the changes in the free height of the GBRP composite coil springs exceeded those of their steel counterparts by 47% and 162.5%, respectively. Notably, these tests revealed no discernible surface failures or fractures on the composite springs. To elucidate the changes in free height observed post-testing, scanning electron microscopy was employed to assess the incurred damage. Furthermore, results from the chipping resistance tests substantiated that the GBRP composite's safety attributes were not compromised by any surface damage.

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Data Availability

The datasets used and/or analyzed during the current study available from the corresponding author on reasonable request.

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Acknowledgements

This research was conducted as part of Youngwire project titled “Development of high-durability composite coil springs.”

Funding

This work was supported by Hyundai Motor Company in 2018 and Youngwire in 2019.

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Authors and Affiliations

  1. R&D Team, Steel Division, Youngwire, Boryeong, 33448, Korea

    Jaeki Kwon

  2. R&D Center, Automotive Division, Youngwire, Boryeong, 33448, Korea

    Jungil Jeon & Jungkyu Shin

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  1. Jaeki Kwon
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Contributions

JK led the conception and design of the study, carried out the experiments, analyzed the data, and drafted the manuscript, providing the key conceptual ideas and proof outline. JJ significantly contributed to the manuscript by reviewing and editing it, as well as analyzing the data. JS played a crucial role in designing and implementing the research, reviewing and editing the manuscript, and conducting the numerical analysis and experimentation.

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Correspondence to Jungkyu Shin.

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Kwon, J., Jeon, J. & Shin, J. Evaluating the Reliability of Glass-Braid-Reinforced Polymer Composite Coil Spring for Automotive Suspension Development Using Finite Element Method and Empirical Tests. Fibers Polym 24, 4031–4047 (2023). https://doi.org/10.1007/s12221-023-00368-5

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