Static structural CAE analysis of symmetrical 65Si7 leaf springs in automotive vehicles

Abstract

Leaf springs in vehicles are used to absorb, store and release energy. During this cycle stresses induced in the springs must not exceed design stress, in order to avoid settling or premature failure. Number of experiments are done in order to determine the stresses, load rate and deflection, which involves lot of time and cost. Today, the technologies in leaf springs are changing gradually; therefore new tools are required to keep aligned with worldwide technological requirements. The work presented in this paper provides a CAE solution to static analysis of 65Si7 leaf springs used in light commercial vehicles (LCV’s). A practical model of leaf spring used in LCV has been taken into consideration for this study. It has been experimentally tested for deflection, stress and load rate on a full scale leaf spring testing machine. A static structural CAE analysis of leaf spring has been done under similar loading condition. The CAD model of the leaf spring has been prepared in solid works and analyzed using ANSYS. Using CAE tools, ideal type of contact and meshing elements have been proposed to achieve results closer to the experimental results. The analytical method for static analysis of the leaf springs has also been described. CAE results have been compared with experimental and analytical results for validation.