Design and Structural Analysis of Composite Leaf Spring Joints with Additional end Lay-Up for Enhanced Vehicle Performance

Abstract

So, in an effort to improve fuel efficiency, ride comfort, and overall vehicle durability, the automobile industry is more and more leaning toward suspension systems that are lightweight as well as high-performance, even if it sounds demanding. Even though conventional steel leaf springs are used widely in commercial and passenger cars, they still bring a bunch of issues, like too much mass, stress concentration, corrosion, and a reduced fatigue life when the loading repeats under cyclic conditions. Composite materials seem like a good choice, because they offer a strong strength-to-weight ratio, corrosion resistance, and also better vibration damping in practice. This study, is basically investigating the structural behaviour and performance upgrade of composite leaf spring joints, specifically when they are reinforced with extra end lay-up configurations, so the joint response can be seen in a more detailed way. Among the key goals of the research are the reduction of stress concentration near the eye-end joints, the improvement of fatigue resistance, the reduction of overall weight, and the enhancement of the effectiveness of vehicle suspension. An approach that was based on finite element analysis (FEA) was utilised in the research project. CAD modelling and ANSYS Workbench simulation tools were utilised, respectively. After careful consideration, the E-Glass/Epoxy composite material was chosen for the design of the leaf spring because of its low weight and high mechanical performance. Under static loading circumstances, structural metrics such as equivalent stress, deformation, stiffness, fatigue behaviour, and weight reduction were examined and compared with typical steel leaf springs. The research showed that the reinforced composite leaf spring was able to achieve a weight reduction of about 65 percent, a considerable reduction in stress concentration, and an improvement in vibration absorption and ride comfort. The additional end layout improved load distribution and structural stability at critical joint sites. The researchers found that reinforced composite leaf springs are more reliable and effective than steel suspension systems for lightweight vehicles.