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ISSN 2395-1621

International Engineering Research Journal (IERJ) Special Issue 2 Page 5211-5216, 2015, ISSN 2395-1621

Vibration Analysis of Hybrid

Composite Leaf Spring
#1

Mr.Shivaji B. Jadhav, #2Prof. Mr.V.H.Waghmare,

1

jadhavshivaji1990@gmail.com

#12

Mechanical Engineering, University of Pune

DGOI COE Swami-Chicholi, Dund, India

ABSTRACT

ARTICLE INFO

This Project Vibration analysis plays a very important role in the design of
composite leaf spring, since the failure due to vibration is more prominent rather than
material failure. The heavy & light vehicles need a good suspension system that can
deliver a good ride and handling. At the same time, it needs to be lightweight and have
an excellent fatigue life. Springs are crucial suspension elements in cars necessary to
minimize the vertical vibrations, impacts and bumps due to road irregularities and
create a comfortable ride. Vertical vibrations and impacts are buffered by variations in
the spring deflection so that potential energy is stored in spring as strain energy and
then releases slowly. So increasing the strain energy capacity of the leaf spring ensures a
more compliant suspension system. Therefore, material with maximum strength and
minimum modulus of elasticity in the longitudinal direction is the most suitable material
for a leaf spring.Composite materials are now used extensively in the automotive
industry to take the place of metal parts. So it is essential to provide hybrid composite
leaf spring with reduced spring rate, which evenly distributes glass fibers and carbon
fibers, graphite fiber throughout resin matrix. The hybrid composite materials offer the
various advantages like maximum strength, minimum modulus of elasticity in the
longitudinal direction, weight & vibration reduction, improved packaging, strain energy
capacity, improved durability & fatigue life and cost reduction due to the use of glass
fibers & carbon fibers over the conventional composites materials. This research work
an attempt has been made to predict the vibration behavior of leaf spring under
dynamic forces and to check the suitability of composite materials combination like EGlass/ Epoxy, & Carbon/Epoxy commercial vehicle leaf spring First the modal analysis
is performed to determine the Eigen values (natural frequencies) and mode shapes
(Eigen vectors), Harmonic analysis is carried out to determine the amplitude of
response and random vibration analysis is carried out for smooth and rough road
excitations using FFT solver & ANSYS V10. Obtained results show Hybrid material (Eglass fiber/ epoxy & Carbon fiber) suitable composite material for leaf Spring from
vibration point of view.

Article History

Keywords

Received
2015

:18th

November

Received in revised form :

19th November 2015
Accepted : 21st November ,
2015
Published online :
22nd November 2015

leaf spring, composite, Conventional steel leaf spring

I. INTRODUCTION
Composite Materials:
A
Composite Materials is
defined as a Material composed of two or more constituents
on a macroscopic scale and chemical bonds.

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Typical
composite
Materials
are
composed of inclusion suspended in a matrix. The
constituents retain their identities in the composite.
Normally the component can be physically identified and
there is an interface between them.

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International Engineering Research Journal (IERJ) Special Issue 2 Page 5211-5216, 2015, ISSN 2395-1621

Many composite materials (carbon fiber/eglass fiber/e-graphite fiber.) offer a combination of strength
Parameters
Value
Total length of the spring (Eye to Eye)

965mm

Free camber (At no load condition)

165mm

Thickness of leaf

10mm

Width of leaf spring

50mm

Maximum load given on spring

1000N

and modulus that are either comfortable to or better than any

traditional metallic materials. Because of their low specific
gravities, the strength weight-ratio and modulus weight-ratio
of these composite materials are markedly superior to those
of metallic materials. The fatigue strength weight ratios as
well as fatigue damage tolerance of many composite
laminates excellent. For these reasons, fiber composite have
emerged as major class of structural material and are either
used or being considered as substitution for metal in many
weight critical components in aerospace, automotive and
other industrials. Another unique characteristic of many
fiber reinforced composite is their high internal damping.
This leads to better vibration energy absorption within the
materials and result in reduces transmission of noise and
vibration to neighboring structures.

EZ(MPa)

6500

10600

PRXY

0.27

0.27

PRYZ

0.06

0.02

PRZX

0.06

0.02

GX(MPa)

4500

7600

GY(MPa)

2500

2500

GZ(MPa)

2500

2500

10

P(kg/mm3)

0.000002

0.0000016

fabrication of composite mono leaf spring:

handlay up method:

Geometry Detail:
CATIA Modeling of any project is one of
the most time consuming process. One cannot shoot directly
from the form sketches to Finite Element Model. CATIA
(Geometry) Modeling is the base of any project. Finite
Element software will consider shapes, whatever is made in
CATIA model. CATIA modeling of the mono Leaf Spring
structure is performed by using Ansys Design Modeler
software as per mention dimension in below table. The
Geometry of leaf spring used for analysis is shown in fig.
below.

1.cutting of fibers:
for this project we had taken the fiber material as e-glass &
carbon fiber. thisfiber is available in sheet format. tisfiber
sheet is cut by composite scissor. the made leaf spring is
sandwich, top and bottom layer made for e-glass fiber&
medal part is made carbon fiber the dimensions for cutting
lamina are 1200(mm) x 65(mm).
the thickness of carbon fiber is 5 mm, & the two layer of eglass fiber is 2 mm each.
2.preparation of matrix (epoxy):
in preparation of matrix we used two solution named resin
and hardener. the resin is epolom 5015 and hardener was
polyoxyalkelenamine. the material is selected as per
guidance of material expert.
3.fabrication:
first take the wood pattern, on which keep plastic bagging
first as per the dimension available. on the bagging keep
peel ply of same dimension. the bagging is required to leak
proof fabrication or the resin should be in contact with the
pattern. resin is sticky in nature and hence the contact to
pattern should avoid. peel ply is required for the finishing of
required component.

FIG1. 3D MODEL OF LEAF SPRING

Specification of Leaf Spring:

Table Leaf spring specification
Material: Glass Fiber, Carbon Fiber
PROPERTIES OF COMPOSITES
Sr.no
Properties
E-glass

Carbon

EX(MPa)

43000

177000

EY(MPa)

6500

10600

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now, keep first sheet of fiber, apply the matrix over the first
fiber sheet. apply matrix such that all air should be removed.
now, keep second lamina over the applied matrix and again
apply matrix as discussed above. same process in carbon
fiber continue this process for till the last fiber sheet. after
completion of 8 layers of carbon fiber& 8 layers of e-glass
fiber keep above it again peel ply and plastic bagging. after
applying matrix keep this arrangement to dry at least for 24
hrs. the curing time of this matrix is 24 hrs.

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International Engineering Research Journal (IERJ) Special Issue 2 Page 5211-5216, 2015, ISSN 2395-1621

II .METHODOLOGY

Preparation of mathematical model for analytical

method, 3D Modeling using CATIA / Pro-E software
Synthesis of hybrid composite materials for multi leaf
springs
Physicochemical characterization of as-synthesized
hybrid composite materials
Fabrication of multi leaf springs of hybrid composite
materials at optimized parameters generated during
mathematical modeling for analytical method
Finite Element Analysis using ANSYS 10.0 Package
Fatigue testing (such as stiffness, stress and fatigue
life etc.) of hybrid composite leaf springs
Generation of correlation between synthesis
parameters - processing parameters performance of
springs.
Optimization of parameters, result, analysis &
discussion
Compare the results obtained with the data reported
for the prior art materials of multi leaf spring and
conclusions.

III MODAL ANALYSIS

Modal Analysis Basics:
The goal of modal analysis in structural mechanics is to
determine the natural mode shapes and frequencies of an
object or structure during free vibration. It is common to use
the finite element method (FEM) to perform this analysis
because, like other calculations using the FEM, the object
being analyzed can have arbitrary shape and the results of
the calculations are acceptable. The types of equations
which arise from modal analysis are those seen in eigen
systems. The physical interpretation of the eigenvalues and
eigenvectors which come from solving the system are that
they represent the frequencies and corresponding mode
shapes. Sometimes, the only desired modes are the lowest
frequencies because they can be the most prominent modes
at which the object will vibrate, dominating all the higher
frequency mode.
It is also possible to test a physical object to determine
its natural frequencies and mode shapes. This is called an
Experimental Modal Analysis. The results of the physical
test can be used to calibrate a finite element model to
determine if the underlying assumptions made were correct
(for example, correct material properties and boundary
conditions were used). For the most basic problem involving
a linear elastic material which obeys Hooke's Law the
matrix equations take the form of a dynamic threedimensional spring mass system. The generalized equation
of motion is given as:
[M][]+[C][]+[K][X]=[F]
Where [M] is the mass matrix, is the 2nd time derivative
of the displacement [U] (i.e., the acceleration), is the
velocity, [C] is a damping matrix, [K] is the stiffness matrix,
and [F] is the force vector. The general problem, with
nonzero damping, is a quadratic eigenvalue problem.
However, for vibrational modal analysis, the damping is
generally ignored, leaving only the 1st and 3rd terms on the
left hand side:
[M][] + [K][X]=[0]

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This is the general form of the Eigen system encountered in

structural engineering using the FEM. To represent the freevibration solutions of the structure harmonic motion is
assumed, so that is taken to equal [X] , where is an
eigen value (with units of reciprocal time squared, e.g., ), S2 and the equation reduces to
[M][X] +[K][X] = [0]
In contrast, the equation for static problems is: [K] [X] =
[F] which is expected when all terms having a time
derivative are set to zero. In linear algebra, it is more
common to see the standard form of an Eigen system which
is expressed as:
[A][x] = [x]
Both equations can be seen as the same because if the
general equation is multiplied through by the inverse of the
mass, [M] ^ {-1}, it will take the form of the latter. Because
the lower modes are desired, solving the system more likely
involves the equivalent of multiplying through by the
inverse of the stiffness, [K] ^ {-1}, a process called inverse
iteration. When this is done, the resulting eigenvalues, ,
relate to that of the original by: = 1/ , but the eigenvectors
are the same.
Modal analysis is performed to calculate the natural
frequency & spring mode shaped. This analysis advises to
operate the vehicle such that its excitation frequency does
not match with the natural frequency of spring. Hence freefree modal analysis is performed & four modes were
extracted to check the natural frequency & its mode shapes.

IV MODAL ANALYSIS RESULTS

Table: Natural Frequency & Displacement
Mode
No.
1

Frequency(Hz)
16

Max
displacement(mm)
31

47

33

49

46

97

36

106

42

170

35

249

38

256

39

378

45

10

415

69

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International Engineering Research Journal (IERJ) Special Issue 2 Page 5211-5216, 2015, ISSN 2395-1621

Mode Shape 2:
Fig2. Frequency Vs Displacement

Mode Shape 3:
Fig.3Variation of experimental stress of steel and composite springs.

Mode Shape 4:

Fig.4 - Variation of longitudinal stress of steel leaf spring.

Mode Shape 5:

Fig.5 Variation of longitudinal stress of composite leaf spring.

Mode Shape 1

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International Engineering Research Journal (IERJ) Special Issue 2 Page 5211-5216, 2015, ISSN 2395-1621

Mode Shape 6:

FFT Analyzer is devices which will be convert given input

single in a spectrum form. It also converts the time domain
in to frequency domain in to time domain.
V .CONCLUSION

Actual Working Process:

Modes are used as a simple and efficient means of
characterizing resonant vibration. The majority of structures
can be made to resonate. That is, under the proper
conditions, a structure can be made to vibrate with excessive,
sustained, oscillatory motion. Resonant vibration is caused
by an interaction between the inertial and elastic properties
of the materials within a structure. Resonant vibration is
often the cause of, or at least a contributing factor to many
of the vibration related problems that occur in structures and
operating machinery. To better understand any structural
vibration problem, the resonances of a structure need to be
identified and quantified.
Experimental procedure for modal analysis on FFT analyzer:
1)Start the FFT analyzer.
2)Go to run-up mode-set-new set (Rename) - ok.
3)Set the ranges of force amplitude, frequency and scale for
graphs.
4)A force of very small amplitude is applied on a steel leaf
spring by a hammer
Which is provided with FFT analyzer and corresponding
result (NaturalFrequency).
It also gives the amplitudes of a composite leaf spring.
FFT Machine descriptionThe FFT spectrum analyzer is an invaluable tool for
mechanical engineering in todays world of measurement
and analysis of mechanical systems. FFT analyzers are an
essential tool in such fields as vibrations and shock data
analysis, machinery monitoring and analysis of complex
waveforms. Use of the FFT analyzer is required in many
products. Many mechanical engineering today make careers
in the field of vibration and machinery analysis the
knowledge of principles and applications of the FFT
analyzer is essential for the disciplines.

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This work involves the comparison of convention

leaf spring with that of the composite material leaf spring
under static loading conditions the model is preferred of
CATIA V5R19. Then analysis is done through CATIA.
From the result it is concluded that stresses developed in the
composite material leaf spring is less as compared with that
of the steel material leaf spring. So it proves that composite
material is more effective and economical than the
conventional leaf spring with similar design specification.
In this research work, Eigen value, harmonic and
random vibration analysis for steel and hybrid composite
leaf springs is carried out using ANSYS 10. From the
obtained results it can be concluded that,
1.Hybrid Composite spring (Carbon fiber/ Epoxy Glass
Fiber) natural frequency compared to other materials.
2. E-Glass/Epoxy and Carbon fiber are having high
amplitude of response than other materials.
3. Carbon Fiber/ Epoxy E-Glass fiber minimum amplitude
of response.
4. Hybrid composite fiber (Carbon Fiber/ E- Glass Fiber)
has minimum deflection and von mises Stress compared to
other materials.
Hybrid carbon possesses more vibration capacity
than conventional steel leaf spring. And also it has good
performance characteristics as compared with other
materials with similar design specifications.
ACKNOWLEDGMENT
Our heartfelt thanks go to DGOI faculty of
Engineering providing a strong platform to develop
our skills & capabilities. I would like to thanks to our
guide respected teachers for their continuous support
& incentive for us. Last but not least, I would like to
thanks to all these who directly or indirectly help us in
presenting the paper
REFERENCES
1.S. Rajeshand, G.B. Bhaskar, Experimental Investigation
on Laminated Composite Leaf Springs Subjected to Cyclic
Loading S. Rajesh et al. / International Journal of
engineering and technology (IJET).
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International Engineering Research Journal (IERJ) Special Issue 2 Page 5211-5216, 2015, ISSN 2395-1621

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