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Materials Today: Proceedings 5 (2018) 5716–5721 www.materialstoday.com/proceedings

ICMPC 2017

Design and Analysis of Leaf Spring using Various Composites –

An Overview
K.Ashwini a, Prof C.V. Mohan Raob*
a
Research Scholar, Department of Mechanical Engineering, Kakatiya University, Warangal-506009, INDIA
b
Professor, Department of Mechanical Engineering, Kakatiya University, Warangal-506009, INDIA

Abstract

This review is designed to be a comprehensive source for designing a leaf spring using various composites as the Automobile
industries are showing keen interest for replacing steel leaf spring with that of a composite leaf spring to obtain reduction in
weight, which is an effective measure for energy conservation as it reduces overall fuel consumption of the vehicle.

© 2017 Elsevier Ltd. All rights reserved.

Selection and/or Peer-review under responsibility of 7th International Conference of Materials Processing and Characterization.

Keywords: Leaf Spring; Composite Material; Glass Fibre reinforced Material; Carbon/Epoxy; Hybrid Composites.

Introduction
Conservation of natural sources, economizing energy and increasing competition to reduce weight of an automobile
has been the main focus in present scenario for an automobile manufacturer. A Suspension system of a vehicle is an
area where innovations are carried out regularly. Reduction in weight can be achieved by introducing better
material, design optimization and improved manufacturing processes. The suspension leaf spring is one of the
potential items for weight reduction in automobiles as it accounts for 10-20% of the unsprung weight. The
composite material offers opportunities for substantial weight saving without compromising on load carrying
capacity and stiffness. Many composite materials offer a combination of maximum strength and minimum modulus
of elasticity in the longitudinal direction which is the most suitable material for a leaf spring.

* Corresponding author. Tel.: +91-9966054192;

E-mail address: asu_1480@yahoo.co.in

2214-7853© 2017 Elsevier Ltd. All rights reserved.

Selection and/or Peer-review under responsibility of 7th International Conference of Materials Processing and Characterization.
 K.Ashwini et al./ Materials Today: Proceedings 5 (2018) 5716–5721 5717

Literature Review
Literature Review has been classified into three categories. Leaf spring by Glass reinforced, Carbon reinforced and
Hybrid composites. Each one is explained in brief below.

1. Glass Fibre reinforced material

Gulur Siddaramanna, Shiva Shankar, Sambaga Vijayarangan[1] in their research paper Mono Composite Leaf
spring for light weight vehicle-Design, end joint analysis and testing, designed and manufactured a unidirectional E-
Glass fibre/Epoxy mono composite leaf spring without end joints and composite leaf spring using bonded end joints
using hand lay-up technique. The constant cross section design was selected for continuous reinforcement of fibres
and fabricated using the hand lay-up procedure. The E-Glass fibre selected was woven roving 360 GSM and Epoxy
resin is 520F with hardener 758. The steel and composite leaf springs were tested by leaf spring test rig for defects
like cracks, surface abnormalities etc., Stress analysis using finite element method was done using ANSYS under
static loading for stresses and deflection. Composite leaf spring weight was reduced by 85% than compared to steel
leaf spring. Adhesively bonded end joints enhance the performance of composite leaf spring for delamination and
stress concentration when compared with bolted joints.
Mouleeswaran Senthil Kumar and Sabapathy Vijayarangan[2] has done Analytical and experimental studies on
fatigue life prediction of steel and composite multi leaf spring for light passenger vehicles using Life Data Analysis.
In their study a seven-leaf steel spring used in passenger cars is replaced with a composite multi leaf spring made of
glass/Epoxy composites with same dimensions and same no of leaves. Primary target is to compare their load
carrying capacity, stiffness, weight savings and finally fatigue life of steel and composite leaf spring is predicted. All
calculations are done using ANSYS 7.1 version and the loading conditions are assumed to be static. The element
chosen is SOLID 46 and this allows up to 250 different material layers. To establish contact between the leaves, the
interface elements CONTACT 174 and TARGET 170 are chosen. A fibre volume of 0.6 is used and metal spring
eyes are fixed at both ends. The composite leaf spring is found to have 67.35% lesser stress, 64.95% higher stiffness
and 126.98% higher natural frequency than that of existing steel leaf spring. The conventional multi leaf spring
weighed 13.5 kg whereas E-Glass/Epoxy multi leaf spring weighed only 4.3 kg. Thus, weight reduction of 68.15%
has been achieved and fatigue life of composite leaf spring is higher than that of steel leaf spring.
Y.N.V.Santhosh Kumar and M.Vimal Teja[3] in their research paper Design and analysis of composite leaf spring
deals with replacement of conventional steel leaf spring with a mono composite leaf spring using E-
Glass/Epoxy without change in stiffness for automobile suspension system. The leaf spring was modelled in Pro-E
and imported to ANSYS in IGES format. Solid element named SOLID 187 was used to mesh the model. The
element is defined by 10 nodes having three degrees of freedom at each node. The element has plasticity, hyper
elasticity, creep, stress, stiffening, large deflection and large strain capabilities. The element input data also includes
orthotropic or anisotropic material properties. It was observed that the deflection in the composite leaf spring was
almost equal and had the stiffness as that of steel spring. It was observed that a weight reduction of 60.48% was
achieved when compared to steel leaf spring. In this work a 2-mode shape of the composite leaf spring had a natural
frequency of 1.744 Hz and 1.749 Hz which provides for good ride quality.
M.Venkatesan, D.Helmen Devaraj[4] studied Design and analysis of composite leaf spring in light vehicle and
compared the load carrying capacity, stiffness and weight savings of composite leaf spring made of glass fibre
reinforced polymer with that of steel leaf spring. The design constraints were stresses and deflection. The
dimensions of an existing steel leaf spring of a light commercial vehicle are taken to fabricate a composite multi leaf
spring using E-Glass/Epoxy unidirectional laminates. Static analysis of 2D model of conventional leaf spring is
performed using ANSYS 10 and finite element analysis with full load on 3D model of composite multi leaf spring is
done using ANSYS 10. Compared to steel spring, the composite leaf spring is found to have 67.35% lesser stress,
64.95% higher stiffness and 126.98% higher natural frequency than the existing steel leaf spring. A weight reduction
of 76.4% is achieved by using composite leaf spring.
5718 K.Ashwini et al./ Materials Today: Proceedings 5 (2018) 5716–5721

Ravi Kumar.V, R.Lalitha Narayana, Ch.Srinivas[5] conducted study on Analysis of natural fibre composite leaf
spring. They compared glass fibre reinforced composite(GFRC) leaf spring with a Natural fibre reinforced
composite/Jute – Fibre reinforced composite(NFRC/JFRC) leaf spring. A steel leaf spring material 55Si2Mn90 is
replaced with two types of composite mono leaf spring. By using hand lay-up technique E-Glass/Epoxy and Natural
fibre E-glass/Epoxy leaf springs are fabricated and are experimentally tested on UTM machine at load intervals of
5Kg. Static stress analysis was performed using Finite element methods. Analysis was carried out for
E-Glass/Epoxy and Jute-Glass Epoxy composite leaf spring and the results were compared. Modal analysis was also
done to determine the structure’s vibration characteristics – natural frequencies and mode shapes. Fatigue analysis
was conducted by adapting stress life approach. The results showed that the maximum stress and displacement are
within the limit for both composite materials (Tensile stress 850 N/mm2, Compressive stress 450 N/mm2, Deflection
130mm). Compared to weight of steel leaf spring (9.35 Kgs), 62% and 72% weight reduction is possible for E-
Glass/Epoxy and Natural fibre mono composite leaf spring without affecting the load carrying capacity. The natural
frequency of composite leaf spring is higher than enough from the road frequency to avoid the resonance.
V.Pozhilarasu and T.Parameshwaran Pillai[6] studied Performance analysis of steel leaf spring with composite leaf
spring and fabrication of composite leaf spring. They compared Glass fibre reinforced plastic leaf spring and
conventional leaf spring. Reinforcement material is E-Glass fibre rovings which weighs 360 g per sqm. The Epoxy
resin selected is liquid diglycidyle ether of Bisphenol A type (Araldite LY556) which has a density of 1.15-1.20
g/cm3. The hardener used in Triethylene Tetra amine (TETA-Aradur HY951) which has a density of 0.98 g/cm3.
The volume ratio of hardener to resin is 1:10. Due to low cure shrinkage, Araldite LY556 with hardener HY951
based laminates will be dimensionally stable and free from internal stresses. Hand lay-up technique is used for
fabrication. The experiments were performed on servo controlled universal testing machine. The composite and steel
leaf spring were tested under similar conditions and the results were compared. Leaf spring is modelled in
Unigraphics NX4 software and it is imported in ANSYS 11.0 and analysed under similar conditions and thee results
were presented as graphs.

2. Carbon Fibre Reinforcement

M.Raghavedra, Syed Altaf Hussain, V.Pandurangadu, K. Palani Kumar[7] conducted Modeling and Analysis of
laminated composite leaf spring under the static load condition by using FEA. In this work, the dimensions of an
existing mono steel leaf spring of a Maruti 800 passenger vehicle is taken for modeling and analysis with three
different composite materials namely E-Glass/Epoxy, S-Glass/Epoxy and Carbon/Epoxy subjected to the same load
as that of steel spring. The design constraints were stresses and deflection. The three-different composite mono leaf
springs have been modelled by considering uniform cross section, with unidirectional fibre orientation angle. Static
analysis of a 3 D model has been performed using ANSYS 10.0. Compared to steel the laminated composite mono
leaf spring is found to have 47% lesser stresses, 25-65% higher stiffness, 27-67% higher frequency and weight
reduction of 73-80% is achieved. It was also observed that Carbon/Epoxy laminated composite mono leaf spring has
superior strength and stiffness and lesser in weight compared to steel and other composite materials considered in
this investigation.
Sorathiya Mehul, Dhaval B Shah, Vipul Bhojawala[8] studied Analysis of composite leaf spring using FEA for light
vehicle mini truck. The objective is to compare load carrying capacity, stiffness and weight savings of composite
leaf spring with that of steel leaf spring. The dimensions of an existing conventional steel leaf spring were used in
composite multi leaf spring using Carbon Epoxy and Graphite/Epoxy unidirectional laminates. The design
constraints are stresses and deflection. The 3-different composite mono leaf springs have been modelled by
considering uniform cross section, with unidirectional fibre orientation angle for each lamina of a laminate. Static
analysis of a 3D model has been performed using ANSYS 10.0. A weight reduction of 79.617% is achieved by
using composite leaf spring and if mono leaf spring is considered then weight reduction is achieved by 90.09%.
Pankaj Saini, Ashish Goel, Dushyant Kumar[9] studied Design and analysis of composite leaf spring for light
vehicles. The material selected was glass fibre reinforced polymer (E-Glass/Epoxy), Carbon Epoxy and Graphite
Epoxy is used against conventional steel leaf spring. The leaf spring was modelled in AUTOCAD 2012 and the
analysis was done using ANSYS 9.0 software. Constant cross section design was selected to accommodate
continuous reinforcement of fibres. The steel leaf spring material is usually plain carbon steel having 0.90 to 1.0%
 K.Ashwini et al./ Materials Today: Proceedings 5 (2018) 5716–5721 5719

carbon. From the static analysis results, it is found that there is a maximum displacement of 10.16mm in the steel
leaf spring and the corresponding displacements in E-Glass/Epoxy, Graphite/Epoxy and Carbon/Epoxy are 15mm,
15.75mm and 16..21mm. Vonmises stress in the steel is 453.92 MPa whereas in E-Glass/Epoxy, Graphite/Epoxy
and Carbon/Epoxy is 163.22 MPa, 653.68 MPa and 300.3 MPa respectively. Composite mono leaf spring reduces
the weight by 81.22% for E-Glass/Epoxy, 91.95% for Graphite/Epoxy and 90.51% for Carbon/Epoxy over
conventional steel leaf spring.
Surekha S Sangale, Dr. Kishor B Kale, Dighe Y.S[10] conducted Design analysis of Carbon/Epoxy composite leaf
spring. The objective of this work was to compare load carrying capacity, stresses, deflection and weight savings of
composite leaf spring using Carbon/Epoxy with that of steel leaf spring. Unidirectional Carbon/Epoxy composite
material is selected due to high strength to weight ratio and high capacity of storing strain energy in the longitudinal
direction of the fibres. Deflection, bending stress for Carbon/Epoxy and EN47 steel leaf spring were compared and
observed that deflection and bending stress induced in the Carbon/Epoxy is less than the conventional steel leaf
spring for the same load carrying capacity.
Ashvini P Lad, Prof B.S.Gandhare, Prof A.S. Aradhye, Prof N.V. Hargude[11] studied Deflection Analysis of steel
leaf spring Vs composite leaf spring through FEA software. A solid leaf spring was modeled in CATIA. After
modeling, maximum deflection in horizontal and vertical direction are determined by giving upto 150Kg vertical
load in steps of 50Kg rise, at centre of each leaf spring. The deflection was found satisfactory when compared with
regular steel leaf spring with 7% average difference which is acceptable loading deflection. ANSYS results of steel
leaf and Epoxy Carbon fibre leaf are compared and found similar with acceptable range of difference.
Manjunath H.N, Manjunath K, T.Rangaswamy[12] in their research paper Vibration analysis of composite leaf
spring for a light commercial vehicle (TATA ACE) conducted modal analysis to determine the eigen values (natural
frequencies) and mode shapes (eigen vectors), Harmonic analysis was carried out to determine the amplitude of
response. Failure due to vibration is more prominent rather than material failure, an attempt has been made to
predict the vibration behaviour of leaf spring under dynamic forces and to check the suitability of composite
materials like E-Glass/Epoxy, Graphite Epoxy, Boron/Aluminium, Carbon/Epoxy and Kevlar/Epoxy for light
commercial vehicle. Random vibration analysis is carried out for smooth and rough road excitations using FE solver
ANSYS V10. From the results, it was concluded that Boron/Aluminium had high natural frequency compared to
other materials, E-Glass/Epoxy and Kevlar/Epoxy are having high amplitude of response than other materials, Steel
and Boron/Aluminium have minimum amplitude of response, Boron/Aluminium has minimum deflection and
Vonmises stresses compared to other materials. Boron/Aluminium possesses more vibration capacity than
conventional steel leaf spring.
Parkhe Ravindra, Mhaske Raman, Belkar Sanjay[13] studied Modeling and Analysis of carbon fibre Epoxy based
leaf spring under the static load condition by using FEA. An existing mono steel leaf spring of a light vehicle and a
composite mono leaf spring with Carbon/Epoxy was modeled and subjected to the same load. The design constraints
were stresses and deflections. The composite mono leaf spring have been modeled by considering varying cross
section with unidirectional fibre orientation angle for each lamina. Static analysis of a 3D model has been performed
using ANSYS 12.0. Compared to mono steal leaf spring the laminated composite mono leaf spring was found to
have lesser stresses and weight reduction of 22.5% is achieved.
Adapa Mahanth Kumar and B.Sreenivas Kumar Reddy[14] performed Modeling and analysis of mono composite
leaf spring under dynamic load condition using FEA for Light commercial vehicle. The main target is to replace the
multi leaf steel spring by mono composite leaf spring for the same load carrying capacity and stiffness by comparing
stresses and frequencies. Mono composite leaf spring is designed for the same specification except thickness so as to
obtain the same stiffness for the same load carrying capacity and boundary conditions. For this three-different
composite materials E-Glass/Epoxy, Graphite/Epoxy and Carbon/Epoxy have been considered. Modeling is done in
CATIA V5 R19 and analysis is carried out by using ANSYS 15.0 software. It was observed that the stress in E-
Glass/Epoxy is less than the stress in steel as well other composite leaf springs.
5720 K.Ashwini et al./ Materials Today: Proceedings 5 (2018) 5716–5721

3. Hybrid Composites
Vinay K.M, Manujesh B.J[15] studied about Design and fabrication of Hybrid composite springs. This work deals
with replacement of steel leaf spring with hybrid composite spring. For this five different types of springs were
manufactured using Epoxy, Glass Fibre and Silk with constant cross section, varying volume fraction (40 Epoxy:45
E-Glass:15 Silk, 40 Epoxy:30 E-Glass:30 Silk, 40 Epoxy:15 E-Glass:45 Silk, 50 Epoxy:50 E-Glass, 50 Epoxy:50
Silk Fibre). Mechanical tests were carried out to assess the credibility of the designed leaf blades. The leaf springs
were manufactured by hand lay-up technique and to facilitate the wetting of fibres, Epoxy resin with 2hours pot life
was selected. The fabricated specimens were trimmed at the eye section. Young’s Modulus and Ultimate tensile
strength values of the specimens were observed by the tensile testing setup. Most of the specimens failed in the
specified gauge length and almost at the mid-section. The highest modulus is observed in 40:45:15 and lowest
modulus and Ultimate tensile strength is observed for silk fibre reinforced composites. The flexural test (3-point
bending) has been conducted by using bending test fixtures on computerized UTM. The load Vs deflection curves
has been plotted. Inter laminar shear strength (ILSS) test for the different composite laminate were obtained.
Flexural and tensile properties are better for a composite have revealed higher strength and modulus. It was also
observed that stiffness was good in 40:45:15 specimen and concluded that hybridization affects mechanical
properties of the composites.
Keshavamurthy Y.C, Chetan H.S, Dhanush C and Nithish Prabhu. T[16] carried out Design and finite element
analysis of hybrid composites mono leaf spring. In this work a hybrid composite spring composed of E-Glass/Epoxy
and Carbon/Epoxy is designed and analysed using ANSYS. The amount of energy stored varies directly with the
square of maximum permissible stress and inversely to the modulus of elasticity both acting in the longitudinal
direction. If the lay-up is unidirectional, it is subjected to failure when load is applied in other directions. This
phenomenon of failure of material is called delamination. Therefore, the layers with different directions are laid. In
this work, the lay-up is (450/00/900 450/00/900/450) which is used to strengthen it in all directions. Seven elements
constitute one layer and similar pattern is followed till we acquire the desired thickness. The method of achieving
hybrid composite is the deposition of a thin layer of carbon on the template and then the gel is applied uniformly on
the mould which has good surface finish and then apply a uniform layer of Epoxy resin. Later, layer of glass fibre is
layered and Epoxy is applied and this process of stacking continues till the desired dimensions are obtained. The
finite element results displaying stresses and deflections are plotted. Compared to the conventional steel spring, the
hybridized composite spring experience far lower stresses and the spring weight without eye units is nearly 55%
lower, 70% lower stresses.
B.Arun,P.Chithambaranatham[17] studied Static analysis of hybrid composite leaf spring. This paper is aimed to
investigate the suitability of natural and synthetic fibre reinforced hybrid composite material in automobile leaf
spring application. By using natural fibres, efforts have been made to reduce the cost and weight of leaf spring. A
hybrid composite leaf spring with Jute/E-Glass/Epoxy composite material is modeled and subjected to the same
load as that of steel spring. Static structural analysis of a leaf spring has been performed using ANSYS 14.
Deflection of hybrid composite leaf spring is less as compared to steel leaf spring with the same loading condition.
The stress of steel and hybrid composite leaf spring is approximately same. From the results, it was observed that
the hybrid composite leaf spring is lighter and more economical than steel leaf spring.
M.Sureshkumar, Dr.P.Tamilselvam, G.Tharanitharan[18] conducted Experimental investigation of hybrid fibre
mono composite leaf spring for automobile applications. In this study the material selected was Glass fibre
reinforced plastic(GFRC) and Kevlar fibre reinforced plastic. A spring with constant width and thickness was
fabricated by hand lay-up technique. Experimental results are compared with the existing steel leaf spring. The
report proved that the composite material chosen (Glass and Kevlar fibre reinforced plastic) can withstand
maximum load, maximum deformation and maximum stress and can be used to create compact suspension systems.
Conclusion
This review provides a brief summary on the work carried out for designing and analyses of composite leaf spring.
Many of the authors suggested various methods of designing, manufacturing and analyses of composite leaf spring
to reduce the overall weight and increase strength of the leaf spring. For this, various composite materials were used.
Static, Fatigue and Modal analysis were performed using experimental and analytical methods. Some of the
software packages such as CATIA, PRO/Engineer, CAE, ANSYS were used for designing and analyses apart from
 K.Ashwini et al./ Materials Today: Proceedings 5 (2018) 5716–5721 5721

fabrication procedures and compared with steel leaf spring. From various research papers, it is concluded that
compared to conventional mono and multi steel leaf spring, composite leaf spring have less weight, stresses,
vibration and increasing strength, fatigue life and ride comfort. As a result, composites provide a promising future
and is an effective replacement for the existing steel leaf spring in automobiles.

Reference
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