FE Analysis of Parabolic Leaf Spring with Military and

Reinforced Eye Ends using CAE Tools

A
Dissertation submitted to the
Department of Mechanical Engineering
In the partial fulfillment of the requirement for the award of degree of
MASTER OF TECHNOLOGY
IN
MECHANICAL ENGINEERING
(MACHINE DESIGN)
By
Ishan Aggarwal
3133624
Under the esteemed guidance of
Dr. Gian Bhushan

Dr. Pankaj Chandna

Professor

Professor

Mechanical Engineering Department

Mechanical Engineering Department

NIT Kurukshetra, India

NIT Kurukshetra, India

National Institute of Technology

Kurukshetra

CERTIFICATE
This is to certify that the work, which is being presented in the thesis, entitled FE
Analysis of Parabolic Leaf Spring with Military and Reinforced Eye Ends using
CAE Tools by Mr. Ishan Aggarwal in fulfillment of requirement for the award of
degree of Master of Technology in Mechanical Engineering

(Machine Design)

submitted in the Department of Mechanical Engineering at National Institute of

Technology, Kurukshetra is an authentic record of original work carried out by him
under our supervision in conformity with the rules and regulations of the institute.
The matter presented in this thesis has not been submitted in any other
University/Institute for the award of any diploma and degree.

(Dr. Gian Bhushan)

(Dr. Pankaj Chandna)

Professor

Professor

Mechanical Engineering Department

Mechanical Engineering Department

NIT Kurukshetra, India

NIT Kurukshetra, India

ABSTRACT
Continuously changing technologies, increased competition and development of
advanced materials has forced industries to bring new products to the market in least
possible time and with least cost involved in the preliminary design. The above factors
leads to increased design complexities and number of iterations in the design process
of mechanical systems and components. Increased design iterations leads to repeated
experiments which is economically not feasible and also time taking. This leads to
increased use of the computer aided engineering (CAE) tools such as computer aided
design (CAD), computational fluid dynamics (CFD) etc. Various software packages
like ANSYS, ABAQUS, and NASTRAN etc. have evolved on these basis and are
capable of solving structure, thermal, electromagnetic, flow, noise, various
multiphysics problems and design optimization.
The subject of this thesis analyses the static structure analysis of reinforced and military
eye ends of a four layer symmetrical parabolic leaf spring using CAE tools. Analysis
method has been provided for both eye ends using ANSYS. This ensures improvement
in design with minimum actual experimental validation for each design iteration. The
completion of the thesis is carried out in two major steps.
First stage involves the validation of CAE tools used. Assembly CAD model of the
reinforced and military eye ends are generated. The 3D CAD models are complex
assemblies of 11 parts each. CAD models are generated using SOLIDWORKS and
imported to ANSYS for preprocessing. Preprocessing includes material definition,
contact definition, meshing and boundary condition definition. After preprocessing the
structure analysis is carried out in static load conditions for four type of loading
conditions. The analysis results are then post processed for the maximum deformation
ii

and Von-Mises stress distribution. For validation, the results of the reinforced eye end
parabolic leaf spring using CAE tools are compared with the experimental results.
These are found in accordance with experimental results with a variation of 7.6 % in
load deflection rate. The result is a validated design and analysis procedure which forms
the base of mechanical model.
Once validated the second stage involves the comparison of the maximum deformation
and Von-Mises plot for the reinforced and military eye ends using CAE tools. In both
eye ends the post processing results are found to be almost. Deformation is slightly
lower in Military eye because of high stiffness and Von-Mises stresses are slightly more
but well below the material yield stress value.

iii

ACKNOWLEDGMENTS
I would like to express my sincere thanks and gratitude to Dr. Gian Bhushan and Dr.
Pankaj Chandna for their continued guidance and encouragement during this work.
Their contribution of time and technical expertise during this work has been of great
importance. I also thank them for all their patience and excellent supervision.
I would also like to give my special thanks to Mr. Vinkel Arora, Assistant Professor
(NIFTEM) for his valuable contribution and inspiring guidance for this dissertation. I
also extend my thanks to him for valuable feedbacks and necessary suggestions.
I express my gratitude to Dr. Dixit Garg for his support in providing various
departmental facilities which makes this work possible in smooth manner.
I would like to thank my colleague Ishan Aggarwal for his continuous support and
knowledge sharing during whole the time of this dissertation work. In end I extend my
gratitude to each and every person who directly or indirectly has been associated to this
work and during my stay here making it a learning experience of my life.

iv

DEDICATION
This work is dedicated to my mother and sister for all the encouragement, love, patience
and support in completion of this project. I also thank them for all the sacrifices they
made to enlighten my life.

TABLE OF CONTENTS
Chapter

Page

CERTIFICATE ............................................................................................................... i
ABSTRACT...................................................................................................................ii
ACKNOWLEDGMENTS ............................................................................................ iv
DEDICATION ............................................................................................................... v
TABLE OF CONTENTS.............................................................................................. vi
LIST OF TABLES ..................................................................................................... viii
LIST OF FIGURES ...................................................................................................... ix
CHAPTER I: Introduction ............................................................................................. 1
1.1 Background .......................................................................................................... 2
1.1.1 Springs .......................................................................................................... 2
1.1.2 Leaf Springs .................................................................................................. 4
1.1.3 Classification of Leaf Springs....................................................................... 6
1.1.4 CAE and Its Tools......................................................................................... 8
1.1.5 Computer Aided Design (CAD) ................................................................. 10
1.1.6 Finite Element Analysis (FEA) and Its Tools ............................................. 12
1.2 Thesis Objectives ............................................................................................... 15
1.3 Organization of the thesis .................................................................................. 15
CHAPTER II: Background and Literature Review ..................................................... 18
2.1 Literature Review............................................................................................... 18
2.2 Gaps in Literature .............................................................................................. 25
2.3 Problem Formulation and Statement ................................................................. 27
CHAPTER III: METHODOLOGY ............................................................................. 28
3.1 Parametric CAD Modelling ............................................................................... 28
vi

3.1.1 Part Modelling ............................................................................................ 29

3.1.2 Assembly Modelling ................................................................................... 30
3.2 CAE Static Structure Analysis using ANSYS WB............................................ 31
3.2.1 Material Definition...................................................................................... 34
3.2.2 Geometry..................................................................................................... 34
3.2.3 Contact Definition....................................................................................... 35
3.2.4 Meshing....................................................................................................... 37
3.2.5 Boundary Conditions .................................................................................. 38
3.2.6 Solution ....................................................................................................... 40
CHAPTER IV: RESULTS AND DISCUSSIONS ...................................................... 41
4.1 FEA Results of Reinforced Eye End Parabolic Leaf Spring ............................. 41
4.1.1 Experimental Load Deflection Curve for Reinforced Eye End .................. 45
4.1.2 Comparison of FEA Load Deflection Curve and Experimental Load
Deflection Curve .................................................................................................. 46
4.2 FEA Results of Military Wrapper Eye Parabolic Leaf Spring .......................... 47
4.2.1 Comparison of FEA results for Reinforced and Military wrapper eye ....... 51
CHAPTER V: CONCLUSION.................................................................................... 52
CHAPTER VI: FUTURE SCOPE ............................................................................... 53
REFERENCES ............................................................................................................ 54
Appendix A .................................................................................................................. 56
List of Publications .................................................................................................. 56

vii

LIST OF TABLES
Table

Page

Table 1: Material properties of SUP 11A .................................................................... 34

Table 2: Comparison of FEA results for Reinforced and Military wrapper eye ......... 51

viii

LIST OF FIGURES
Figure

Page

Figure 1: Helical Springs Employed in Suspension ...................................................... 3

Figure 2: Elliptical leaf spring ....................................................................................... 3
Figure 3: Coil Spring ..................................................................................................... 3
Figure 4: Belleville Springs ........................................................................................... 3
Figure 5: Leaf Spring attached to automobile suspension ............................................. 5
Figure 6: Upturned eye .................................................................................................. 7
Figure 7: Military eye .................................................................................................... 7
Figure 8: Downturned eye ............................................................................................. 7
Figure 9: Berlin eye ....................................................................................................... 8
Figure 10: Welded eye ................................................................................................... 8
Figure 11: Oval eye........................................................................................................ 8
Figure 12: 2D drawing of the parabolic leaf spring ..................................................... 29
Figure 13: Bill of Materials.......................................................................................... 29
Figure 14: Part modelling of main and second leaf of parabolic leaf spring ............... 30
Figure 15: Assembly model of parabolic leaf spring with reinforced eye end ............ 31
Figure 16: Assembly model of parabolic leaf spring with military wrapper eye end.. 32
Figure 17: CAD geometry imported to ANSYS for reinforced eye end ..................... 33
Figure 18: CAD geometry imported to ANSYS for military wrapper eye end ........... 33
Figure 19: Contact definition in reinforced eye end parabolic leaf spring .................. 36
Figure 20: Contact definition in military wrapper eye end parabolic leaf spring ........ 37
Figure 21: Meshed 3D model for reinforced eye end .................................................. 38
Figure 22: Meshed 3D model for military wrapper eye end........................................ 38
Figure 23: Boundary conditions applied to reinforced eye end ................................... 39
ix

Figure 24: Boundary conditions applied to military wrapper eye end......................... 39

Figure 25: Deflection at specified load for reinforced eye end ................................... 42
Figure 26: Equivalent stresses at specified load for reinforced eye end ...................... 42
Figure 27: Deflection at unladen load for reinforced eye end ..................................... 43
Figure 28: Equivalent stresses at unladen load for reinforced eye end........................ 43
Figure 29: Deflection at laden load for reinforced eye end ......................................... 44
Figure 30: Equivalent stresses at laden load for reinforced eye end............................ 44
Figure 31: Deflection at 2G load for reinforced eye end ............................................. 45
Figure 32: Equivalent stresses at 2G load for reinforced eye end ............................... 45
Figure 33: Experimental results of load vs deflection for reinforced eye end ............. 46
Figure 34: Comparison between CAE and experimental load deflection curve .......... 46
Figure 35: Deflection at specified load for military wrapper eye end ......................... 47
Figure 36: Equivalent stresses at specified load for military wrapper eye end ........... 48
Figure 37: Deflection at unladen load for military wrapper eye end ........................... 48
Figure 38: Equivalent stresses at unladen load for military wrapper eye end ............. 48
Figure 39: Deflection at laden load for military wrapper eye end ............................... 49
Figure 40: Equivalent stresses at laden load for military wrapper eye end ................. 49
Figure 41: Deflection at 2G load for military wrapper eye end ................................... 50
Figure 42: Equivalent stresses at 2G load for military wrapper eye end ..................... 50

CHAPTER I: Introduction
Suspension in automobiles is the link between wheels and the automobile body. It
absorbs sudden and shock loading arising from the road conditions and isolates the
vibration, carries lateral loads, brake torque and driving torque by storing the elastic
energy and releasing that later on. Design criterions, though, for the suspension systems
are more or less based on the strength but comfort conditions are also increasingly
becoming a necessary factor.
For design based on rigidity criterion [19], best approximation is to assume negligible
deformation. Suspension systems however are designed on the basis of flexibility
conditions which is provided by metal bodies with controlled geometries. This
flexibility however can be of linear or nonlinear nature depending upon the nature of
loading.
Springs are the most basic type of suspension systems providing flexible design. One
of the special types of springs are leaf springs and are conventionally referred as mono
and multi leaf springs. Multi Leaf springs are being used in automobiles ranging from
heavy to light commercial vehicles and even the passenger vehicles. These springs
absorb the mechanical energy upon deflection and releases it slowly to reduce the
impact of sudden loads. Constant efforts has been made in order to improve the
efficiency of the springs in the current age of optimization and also the comfort
conditions in modern technological world.
Latest advances in the leaf spring technology are parabolic multi leaf springs. Parabolic
leaf spring are regarded as tapered beams or tapered leafs with thickness maximum at
center of certain length and parabolic at rear and front end with straight extremes. The

advantages of using parabolic leaf spring are seen in weight reductions, have better
fatigue life, surface stresses are constant over the length, minimum interleaf friction and
contacts and ability to reduce the ride clearance providing more stability and comfort
conditions.

1.1 Background
1.1.1 Springs
Springs are essentially the flexible members. These bodies can exhibit flexibility to the
degrees as desired by the design engineer. This flexibility can be linear or nonlinear in
terms of load deflection rate. Flexibility allows temporary distortion for immediate
restoration of function. Springs allow controlled application of force, storing and
release of energy which could be due to shock or vibrations. Other functions include
the control of motion which could be seen in cams and followers to maintain contact,
creation of necessary pressure in friction surfaces such as clutches and brakes,
restoration of machine parts to their original position such as in governors or valves.
Springs are also employed in spring balances and gauges for measuring forces and
storage of energy in clocks. [20]. Because of advantages to designers, springs have been
extensively studied and mass production is carried out. Different configurations of the
design have led to their use in wide variety of mechanical applications.
Generally springs are classified as wire springs, flat springs, or special-shaped springs,
and each of these divisions is having its own classification also. Wire springs include
helical springs of round or square wire, made to resist and deflect under tensile,
compressive, or torsional loads. Flat springs mainly include cantilever and elliptical
types regarded as leaf spring, motor or clock type power springs, and flat spring
washers, usually referred as Belleville springs. General spring materials used are

Chromium Vanadium, Chrome Silicon, Music wire, Stainless steel, Phosphorus

Bronze, Spring Brass etc.

Figure 1: Helical Springs Employed in Suspension

Figure 2: Elliptical leaf spring

Figure 3: Coil Spring

Figure 4: Belleville Springs

3

1.1.2 Leaf Springs

Leaf springs are one of the important safety elements in the vehicle suspension system.
The primary purpose of the leaf spring is to isolate the vibrations by absorbing and then
releasing energy thereby providing the necessary comfort conditions. These are usually
of the shape of slender arcs and are referred as semi elliptical springs. Generally the
material used is spring steel and are of rectangular cross section. Axle is located at the
center of the arc and tie holes are provided at either ends for attaching the vehicle
chassis. Leaf springs have the advantage of being guided along a specified path. In order
to facilitate the movement along definite path one end of the leaf spring should be
connected to shackle regarded as short swinging arm and other end be fixed to the frame
of the vehicle or chassis. Leaf springs are commonly used in automobiles ranging from
medium commercial vehicles to heavy commercial vehicles.
Other commonly used materials for leaf springs are Plain carbon steel, Chromium
vanadium steel, Chromium- Nickel- Molybdenum steel, Silicon- manganese steel etc.
leaf springs for heavy load applications are made from several leaves stacked one above
the other in several layers and with progressively shorter leaves. Longest leaf is called
as main leaf and is rolled at both ends to form the eyes. Various leaves are connected
together by center bolt and these springs are regarded as multi leaf springs. They serve
the purpose of locating and to some extent damping with springing action. The damping
in these springs is facilitate by the interleaf friction which also has disadvantages as it
is difficult to control, causes noise and wear and affects the comfort riding also leading
to hard ride conditions. Leaf spring attached to the automobile suspension can be seen
in Fig. 5.

Figure 5: Leaf Spring attached to automobile suspension

Leaf springs being cantilever beams, always desired to have uniform bending stresses,
which is achieved in parabolic leaf springs by tapered leaves with maximum thickness
at center and varying parabolically towards the ends. Parabolic leaf springs are the latest
advances in the leaf spring technology. This design is characterized by few number of
leaves in comparison to conventional multi leaf springs. The contact is present only at
the ends and at the center of the leaf usually regarded as seat length. Due to parabolic
shape at all other points there is no contact because of spaces. This leads to reduction
in interleaf friction the result of which is soft ride. Parabolic leaf springs are compared
with coil spring suspension in terms of comfort ride. Various advantages of using these
springs are listed as:

Appreciable reduction in weight.

Surface stresses are constant over the length.

Minimum interleaf friction.

Scope for reduction in ride clearance leading to more stability and comfort
conditions.

Better fatigue life.

1.1.3 Classification of Leaf Springs

1. Leaf springs are generally classified as mono leaf springs, multi leaf springs and
parabolic leaf springs.
Mono leaf springs as the name suggests have only one leaf and is called as
main leaf. This leaf is heat treated plate of steel and can be of many
configurations such as constant thickness and constant width design, constant
thickness and varying width design or constant width and varying thickness
design. Varying thickness parabolically or varying width linearly is done in
order to achieve the uniform strength design. These are obsolete now as they
are having safety issues as there is no other leaf to back up the main leaf in case
of failure.
Multi leaf springs are having several leaves which are placed one over other
and are held together with center bolt. These are of flat steel bars of hardened
spring steel obtained after heat treatment and the first leaf is regarded as main
leaf and all other leaves are regarded as supporting leaves. They have edge over
the mono leaf springs in terms of safety as in this case supporting leaves can
support the main leaf in case of any failure condition.
Parabolic leaf spring are the one having tapered leaves having parabolically
varying thickness. The thickness is maximum at the center and varies towards
the end. Top leaf is regarded as main leaf in parabolic leaf springs also and other
leaves as supporting leaves. These are having certain advantages in terms of ride
height, comfort conditions, uniform bending stresses which enables them to be
used increasingly in the modern automobile applications.

2. Classification based on the eye end designs. Based on this these are classified
as standard or upturned eye, military wrapper eye, downturned eye, berlin eye,
welded eye, oval eye etc.
Standard or upturned eye is the most commonly used leaf spring eye end
owing to its ease of manufacturing. Main leaf in this receives support from the
extension of second leaf in some cases.
Military wrapper eye is the design in which the second leaf also has an eye
and it comes in action during rebound operation and provides support to main
leaf. It also has an advantage of continued use in case of failure of main leaf and
its eye.
Downturned eye is used to improve the steering and axle control.
Berlin eye reduces the tendency of the eye to unwrap and load here is applied
through centerline of main plate.
Welded eye is preferable in applications where horizontal force is high. A word
of caution in this is to complete welding before the heat treatment.
Oval eye is preferable to use when different horizontal and vertical rates are
present.

Figure 6: Upturned eye

Figure 7: Military eye

Figure 8: Downturned
eye

Figure 9: Berlin eye

Figure 10: Welded eye

Figure 11: Oval eye

3. Other classifications are based on load, number of eyes, and leaf ends which are
of less particle importance as are rarely used.

1.1.4 CAE and Its Tools

Computer Aided Engineering covers the use of computers in all activities from the
design to the manufacture of a product. It is at the forefront of information technology
and of crucial importance to industries in terms of increase in the productivity, which
is estimated to be increased to double than earlier. Another advantages are seen in terms
of shortened project turnaround times and improved quality and accuracy of the work.
It is now regarded as vital part of many global industries including those of automotive,
aerospace, oil, defense and health etc. In broader terms CAE is the integration of more
than one computer tools which help in automating the design process. It is hence
defined as the use of computer softwares to simulate performance in order to improve
product designs or assist in the resolution of engineering problems. This includes 3D
model generation, simulation, validation, and optimization of products, processes, and
manufacturing tools. Some of the CAE tools commonly used are SolidWorks, CATIA,
I-DEAS, Pro Engineer, ANSYS, ABAQUS, and NX NASTRAN etc. [21, 22,23,24,25,
26, and 27].

Typically CAE process comprises three major steps defined as preprocessing, solving,
and post processing. In the preprocessing phase, engineers model the geometry and the
physical properties of the design using CAD tools. Other details include the
environment in the form of applied loads or constraints. The model is then solved using
an appropriate mathematical formulation as per the physics of the problem. In the postprocessing phase, the results are presented to the engineer for review. Typically CAE
includes the following tools and analysis:

Computer aided design (CAD) tools: Used for physical creation of the
geometry. This may consist of 2-D or 3-D figures/shapes/curves/surfaces.

Computer aided manufacturing (CAM) tools: It is a system of automatically

producing finished products by using computer controlled production machines
Used to generate the programs for the computer numeric controlled (CNC)
machines for production and process scheduling.

Finite element analysis (FEA) and its tools: Used for stress and dynamic
analysis of components and assemblies.

Computational fluid dynamics (CFD): Used for thermal and fluid interactions.

Multi body dynamics (MBD): Used to understand the dynamics behavior of the
Multibody systems under the application of forces. In other words it is the study
of motion under forces. Multibody system mentioned is a system that consists
of solid bodies, or links, that are connected to each other by joints that restrict
their relative motion.

Optimization tools: These are used for the optimization of the products and
processes in simulation.

Rapid Prototyping: Computer Aided Engineering systems also provide virtual

product development environments by the rapid prototyping methods allowing
3D models to be created, analyzed, optimized and stored efficiently. Various
operational and extreme physical conditions can also be evaluated. This leads
to reducing the need for prototypes and actual testing.

The CAE tools used in the current study include the use of CAD tool software
Solidworks and FEA software tool ANSYS.

1.1.5 Computer Aided Design (CAD)

Since recent times the techniques for modelling and simulation are becoming mature.
This leads to increasing implementation by industries of CAD tools. Computer aided
design (CAD) is essentially the mathematical interpretation of shape for use in
computer graphics, manufacturing, or analysis applications. It draws upon the fields of
geometry, computer graphics, numerical analysis, approximation theory, data structures
and computer algebra. Computer Aided Design (CAD) involves the use of computer
hardware and graphics software to generate design drawings.
Modern CAD equipment enables the designer to quickly produce very accurate and
realistic images of products to be manufactured. Current mechanical systems are 3D
systems and have dominance to other application sectors as well. 3D modelling can be
Wire Frame, Surface or Solid Modelling. Wire frames being the first ones to represent
the 3D model are based on representation by edges in form of skeleton of the model.
Surface modeling develops the surface or skin instead of wireframe. In early times these
were based on Fergusson and Bezier curves although in modern times these are replaced
by non-uniform rational B-spline (NURBS) which are capable of modelling almost all
industrial parts. Solid modelling is the latest advances and offers complete
representation of the geometry of part. Solid modeling was in early times based on
constructive solid modeling system referred as CSG system but nowadays use B-Rep
modeling technique to model the topology of the part. Most of the CAD systems
nowadays are Parametric and Feature Based Solid Modelling systems. Parameters are
used to define dimensions, relations between various parameters and also the relations
between various parts of the model. These are defined in terms of positions and size.
Parameterization hence helps to define new part just by changing the values of the
parameters or can define a whole family of parts through the use tables of dimensions.
10

Various operations employed in the solid modelling systems are, 2-D and 3-D
wireframe models, swept, revolved solids, and Booleans as well as parametric editing.
With feature modelling the user can create a variety of holes, slots, pockets, pads,
bosses, cylinders, blocks, cones, spheres, tubes, rods, blends, chamfers and more.
Hollow and thin walled solid models can also be generated.
A beneficiary factor in this is the implementation of three-dimensional (3D) CAD
models into the design stages of product development creating a virtual prototype which
acts as base for further computational simulations. Presently, CAD is not particularly
effective in the initial synthesis of design or in the redesign portion of the design
procedure [28]; however, it is very useful in providing more efficient ways to help the
designer in the design iterations. CAD systems are usually not well integrated with
current simulation techniques although the simulation techniques are well developed.
However, integrated analysis is possible where CAD models can be used for creating
Finite Element Models (FEM) for structural analysis, the procedure employed in the
current study.
Another advantage of using CAD is seen in optimization of the design. Optimization
process can be carried forward with the help of parameterization. Wide changes can be
done quickly to a 3D model throughout if proper parameterization is done. The rapid
development and implementation of new tools allow CAD to be used in a greater part
of the development chain.
Current study uses CAD tool Solidworks. Solidworks is solid modeling CAD software
produced by Dassault Systems Solidworks Corp., a subsidiary of Dassault Systems, S.
A. (France). Building a model in Solidworks usually starts with a 2D sketch consists
of geometry such as points, lines etc. Relations are used to define attributes such as
11

tangency, parallelism, perpendicularity, and concentricity. In an assembly, the analog

to sketch relations are mates. Just as sketch relations define conditions such as tangency,
parallelism, and concentricity with respect to sketch geometry, assembly mates define
equivalent relations with respect to the individual parts or components, allowing the
easy construction of assemblies. Finally, drawings can be created either from parts or
assemblies.

1.1.6 Finite Element Analysis (FEA) and Its Tools

Finite-element analysis is a powerful numerical analysis process widely used in the
analysis of engineering applications. Finite element method (FEM) is a numerical
method for solving a differential or integral equation specifically the partial differential
equations. These equations are converted to a large system of algebraic equations and
solved with the help of computers. Partial differential equations arise in the
mathematical modelling of many physical, chemical and biological phenomena. These
covers very wide areas of applications including aerospace, automobile, medical
devices, fluid and thermal interactions, electromagnetics etc. These equations are so
complicated that finding their exact solutions in closed form or by purely analytical
means (e.g. by Laplace and Fourier transform methods, or in the form of a power series)
is either impossible or impracticable, and one has to resort to seeking numerical
approximations to the unknown analytical solution.
FEA has its origins in structure mechanics. Analysis procedure using FEM involves
dividing it into a number of small building blocks, called finite elements [29]. For this,
the object is first divided into number of elements that forms a model of the real object.
These are interconnected at common points of two or more elements called as nodes.
Commonly used elements are of simple shape such as a square, triangle, or cube or

12

other standard shape for which the governing equations in the form of a stiffness matrix
could be written using algorithms. Finite-Element software assembles the stiffness
matrices for these simple elements to form the global stiffness matrix for the entire
model. This stiffness matrix is solved for the unknown displacements, given the known
forces and boundary conditions. From the displacement at the nodes, the stresses in
each element can then be calculated. The analysis procedure using FEA is divided in
three major steps i.e. Preprocessing, Solution and Post processing. The preprocessing
involves the following steps:
1. Selection of analysis type: Various analysis types which can be commonly
solved by FEA are as follows:

Static Structural Analysis and Transient Structural Analysis.

Modal Analysis

Transient Dynamic Analysis

Buckling Analysis

Contact Analysis

Steady-state Thermal Analysis and Transient Thermal Analysis

Buckling Analysis

Fatigue analysis (cyclic loading) etc.

2. Selection of the elements: In this selection is done from 1D, 2D or 3D elements

types depending upon the physics of the problem.
3. Material properties: The material properties are input in this step on the basis of
material used.
4. Connections definition: Contact or joint definitions are carried out in this step.

13

5. Meshing: Disintegrating the continuous object model into finite number of

elements in order to facilitate the solution to the problem.
6. Loading and boundary conditions: Loading and constraints to the problem are
applied in this step as per the actual environment of the problem.
Next step is the solution to the problem defined in preprocessing stage. During this
stage the element matrices are computed and results are stored in result files. These files
are generated for the next stage of post processing which enables viewing the results in
form of graphic and tabular displays.
Last step in the analysis is the post processing. It gives the detailed output of the analysis
carried out in numerical values and represents the various stress, displacement, thermal
etc. plots for better understanding through graphics. Detailed report of the analysis is
also generated by most of the FEA software packages which is finally followed by
interpretation of the result sad conclusions.
Although the FEA and its software capabilities are already developed to a great extent
but still there are sources of errors which leads to abrupt results. These mainly includes
errors in the 3D modeling of the parts or assemblies. Sketch cleanup is always
recommended in order to minimize these errors. Another major source of error is the
interpretation of the physics of the problem which ultimately leads to error caused by
inappropriate boundary conditions. Restrictions in terms of computer capabilities and
experience of the CAE analyst at industries adds to errors in simulations.
In the current study the FEA tool employed is ANSYS Workbench. ANSYS is an
engineering simulation software (computer-aided engineering, or CAE) developed by
Ansys, Inc., USA. ANSYS is a general purpose finite element modeling package for
14

numerically solving a wide variety of mechanical problems. These problems include

static and dynamic structural analysis (both linear and non-linear), heat transfer and
fluid problems, as well as acoustic and electro-magnetic problems.

1.2 Thesis Objectives

Main objectives are as follows:
1. To understand the static structural capability in terms of total deformation and
Von-Mises plots, of four layer symmetrical parabolic leaf spring having leaves
(with included z bending details in the CAD geometry). Static structure analysis
of both reinforced and military wrapper eye ends to be carried out and also the
validation of the design analysis procedure of reinforced eye end with the
experimental results.
2. To compare the FEA results of validated reinforced eye end and military
wrapper eye and comments on the recommended applications and flexibility of
designs.

1.3 Organization of the thesis

Chapter 1 gives the brief introduction about the springs, leaf springs including
parabolic leaf springs and their design criterion. Detailed background of springs and
leaf springs is discussed in this chapter. Leaf spring considered in this study is also
discussed in details with its advantages. Discussions on the classification of various leaf
springs and their applications is outlined. Following this detailed introduction on
computer aided design and computer aided engineering is carried out to understand the
need to use these techniques in modern design and their tools. This introduction is

15

followed by prime objectives of the current work. In end organization of the thesis is
outlined.
Chapter 2 primarily discusses the literature survey and gaps in literature. Detailed
literature study discussed which covers parabolic and conventional leaf springs. It
covers the various FEA modelling techniques used to understand the static, fatigue and
contact behaviors of leaf springs. The literature survey is followed by gaps in literature
and problem formulation of the current study.
Chapter 3 outlines the actual implementation and methodology to carry out the static
structure analysis in ANSYS for reinforced and military wrapper eye ends. It includes
the methods and procedures to carry out the 3D modeling in Solidworks. Ultimately a
3D CAD model is generated as per specifications. Next step is the analysis after
importing the CAD model. Step by step explanation of the analysis procedure is then
discussed. Preprocessing information explanation includes the details regarding contact
definitions, meshing information and applied boundary conditions. Details of solution
section are discussed in last.
Chapter 4 includes the post processing results of the static structure analysis carried
out in ANSYS for reinforced and military eye ends. Von-Mises plots and total
deformation plots for all sets of loading conditions is presented. Comparative study is
demonstrated with the help of tables and graphs showing various FEA and experimental
results.
Chapter 5 finally concludes the thesis listing the conclusion points.

16

Chapter 6 discusses the future scopes of the current study. It is followed by references
used. Lastly appendix is given which gives the details of publications associated with
the current study.

17

CHAPTER II: Background and Literature Review

Leaf springs are among few mechanical components, of which, design has been evolved
and standardized by the international community. Standard design procedure of a leaf
spring can be found in the SAE manual of leaf spring design [30]. The Bureau of Indian
Standards has also worked towards the standardization of the leaf spring in respect to
international standards [31]. This includes primarily the design and material selection
for the leaf springs. Ample amount of literature, research publications and journals are
present on conventional leaf springs. In this prospectus brief summary regarding spring,
leaf springs and CAE tools is presented in regard to current work.

2.1 Literature Review

W.J. Yu and H.C. Kim [1] worked on double tapered FRP leaf spring so as to replace
that with four leaf spring made of steel. Double tapered shape was achieved by linearly
varying thickness, hyperbolically varying width and constant cross section area along
the length of the spring or in simple words it was regarded as double cantilever beams.
Material chosen for the study is S2-glass/epoxy and E-glass/epoxy. Stress analysis
under static loading conditions of the GRP spring was carried out using FEM software
ANSYS 4.2B by employing quadrilateral shell elements. Tsai-Hill theory was used as
failure criterion and the results were found in accordance with the experimental results.
Additionally flexural fatigue testing was also performed for both the samples to 100000
cycles. S2-glass withstand the required cycles without any failure of operation or
damage reported but E-glass showed some damage on upper surface which was due to
presence of voids on the material surface. Despite damage no loss of spring action was
seen thus not regarded as fatigue failure. Also a prototype GRP leaf spring was also
prepared with concave width profile so that steel fitting could be easily mounted.

18

Andrea Corvi [2] presented a program on preliminary structural analysis of composite

beams based on composite mechanics and finite element method. The element used was
derived using Timoshenko beam theory which allows accounting for shear effects on
beam deflection. The inputs to the program included material properties covering fiber
and matrix properties, 2D meshed beam geometry, loading conditions and constraints.
Finite element analysis was used and nodal displacements and stress were evaluated to
determine failures and structure collapse load. Convergence tests of the solutions were
conducted firstly on structure behavior of isotropic materials with known behavior and
then on the composite beams whose data were already present in the literature. These
results were then compared with FEM results using ABAQUS and NASTRAN in order
to prove programs reliability on general structure. The program was then applied to
understand the structural behavior of a composite mono leaf spring under varying
design parameters. The parameters studied were change in the glass fiber volume
content, use of combined glass and carbon epoxy layers and variation in glass fiber
angle while maintaining other parameters as constant.
E. Zahavi [3] analyzed a conventional multi leaf spring for analysis of contact problem
using ANSYS. Loaded leaf spring was taken for the analysis and the deformation is
related to the contact. The contact problem in the leaf spring under load was found to
be of receding type. Contact was defined by use of one dimensional interface elements
which allows the tangential sliding. Friction was taken in account and because of this,
to converge to solution a new iterative process was developed based on new algorithm.
To stop iterations verification check based on Coulombs friction law was applied.
Deformation plots of loaded spring superimposed on unloaded was shown and also the
forces in interface elements between first and second leaves were plotted.

19

Peiyong et al. [4] carried out the CAE simulation to determine stresses and deformation
under different loading conditions, of a two stage multi leaf spring, a leaf spring
assembly and Hotchkiss suspension. The software used was ABAQUS and effect of
large deformations, interleaf friction and contact were included in the analysis leading
to non-linearity. Analysis was carried out for leaf spring vertical push, leaf spring
assembly vertical push, windup, suspension roll and suspension cornering. The results
of the analysis were found in agreement with the experimental results. The simulation
models presented could be used in development of leaf springs and suspension.
Predicted rates also could be used in full vehicle NVH (Noise, Vibration, and
Harshness) models such as in NASTRAN or MBD (Multi body dynamics) software
packages.
Mahmood M. Shokrieh and Davood Rezaei [5] analyzed a steel leaf spring using
analytical methods as per SAE, finite element methods and finally

comparison

is

made with experimental results for verification. The steel spring selected for study was
unsymmetrical and ANSYS 5.4 is used to carry out FEA. The element used is SOLID
45 and for contacts CONTA 49 to represent sliding and friction between leaves. Stress
analysis was carried out for static and bump condition. The results were found in close
accordance with experimental. The steel leaf spring was then optimized for weight
reduction and material is replaced with E-glass/epoxy which brings about 80 %
reduction in weight. The composite leaf spring was mono leaf spring thus its shape was
optimized by parameterizing width and thickness and objective function was fed as
input. First order method to optimize was selected in ANSYS. The optimized spring
was found to have width decreasing hyperbolically and thickness increasing linearly
form spring wye towards axle seat. The stresses in composite spring were much lower
than the steel spring, natural frequency was higher to avoid resonance.
20

J.P. Hou et al. [6] studied the evolution of the eye end designs of a composite leaf
spring used for the freight rail applications. The material used in the study was glass
fiber reinforced plastic (GRP). FEA study was carried out using MSC-Marc and static
and fatigue analysis was carried out to get stress and deflection results. Three main
designs were studied in which first two designs have integrated eye ends in which skin
tape layers went around the eye and along the leaf body. The problem with the first
design lies in the delamination failure at the interface of the fibers owing to the shear
stress concentration but the FEM results showed that it sustained the static load and
required fatigue cycles. In the second design additional transverse bandage were
provided in the delamination region. Results showed decrease in delamination but not
prevented. In the final design open eye end was used and the results of static and fatigue
analysis were found to be in good agreement and was selected as final design.
Vinkel Kumar Arora et al. [7] presented CAE analysis of a 65Si7 conventional leaf
spring. The CAD model was generated in Solidworks and analysis was carried out using
ANSYS. The CAE results in terms of Von-Mises stress and deformation were
compared with the analytical and experimental results to validate the CAE analysis and
found in acceptable ranges of variation. Load deflection curves were also plotted and
found experimental results show nonlinear relationship between load and deflection
values.
Manas Patnaik et al. [8] studied the mono parabolic leaf spring using FEA and DOE
(Design of Experiments) approach. CAD modeling and analysis was carried out using
CATIA. Effect of camber and eye diameter were selected for study from design of
experiments approach. FE results in terms of Von-Mises stresses and displacement are
evaluated from static structure analysis and were plotted. With the increase in camber

21

there was decrease in displacement and increase in the stresses. With the increase in
eye distance there was increase in displacement, however, the stresses were found to
decrease.
Karthik et al. [9] presented the comparison of CAE fatigue analysis of a parabolic leaf
spring using three materials. The loading used in fatigue analysis was non constant
amplitude proportional loading and CAE tool used in the analysis was ANSYS.
Goodman and Gerber approach for the mean stress correlation theory and life
comparisons were made. Additionally an attempt was made to understand the mean
stress correlations.
F.N. Refngah et al. [10] carried out fatigue life predictions using FEA and comparison
was made between a multi leaf and a parabolic leaf spring. The material of multi leaf
spring was SAE 5160H and that of parabolic leaf spring was SAE 6150. 20 noded hexa
elements were used in meshing and appropriate boundary conditions were applied in
the analysis. Fatigue life predictions using Morrow stress mean correlation model was
done for strain based life calculation under variable amplitude loading. Strain data for
correlation was collected using SoMat eDAQ data acquisition system on a public load.
The collected data was then used as input for FE based fatigue life calculations. No
damage was reported on eyes, however, multi leaf spring experienced high damage at
center owing to stress concentration. Parabolic spring however had distributed stresses.
Krishan Kumar and M.L. Aggarwal [11] worked on CAE analysis of a symmetrical
EN45 parabolic leaf spring consisting of three leaves. CAD model was generated using
CATIA V5 and analysis was carried out using ANSYS 11. The spring in study was a
three layer parabolic spring and meshing was carried out by using relevance, sizing
controls and refinements. Appropriate boundary conditions in terms of joint rotation
22

and vertically applied force at seat length were applied. A stress deflection curve was
plotted for the rated and maximum loading and comparison made with the experimental
results. The curve was linear and CAE results were found to be in accordance with the
experimental results.
J.P. Karthik et al. [12] predicted the fatigue life of parabolic leaf spring using three
different SAE standard materials using two Palmer-Miner rule and Morrows method
under predominantly tensile loading sequence. Study was carried out under non
constant amplitude proportional loading. FE based fatigue analysis was carried out for
both stress and strain life approach. An attempt was also made to understand the effect
of mean stress on fatigue life.
Ahmet Kanbolat et al. [13] presented hybrid method for the fatigue life evaluation
based on non-linear analysis. Evaluation of production parameters and geometric
tolerances were studied. Important parameters affecting fatigue were identified and
CAE study from 2D and 3D models completed. CAE results were in accordance with
the theoretical load deflection curve and effect of heat treatment, quenching etc. were
more than the effects of geometric tolerances.
Y.S. Kong et al. [14] presented the stress behavior using FEM under combination of
vertical and windup loads. CAD model was generated using NX 6 and imported to
Hyperworks for the analysis. 8 noded hexa elements were used to mesh the 3D model
and interleaf friction was assigned to the model. Material selected for the study was
carbon steel. Maximum windup load was assumed to be half of the vertical load and
acting in longitudinal direction. Critical stress regions were identified and stress values
calculated. Results were found to be well within the yield strength criterions. Newly

23

designed spring was having 30 % reduction in weight and 10 % less vertical stiffness
than the conventional multi leaf spring.
Murathan Soner et al. [15] studied non-linear finite element model of a five layer
parabolic spring using Abaqus 6.10 and results of analysis were verified with the
theoretical load deflection diagram. The same spring was then optimized to reduce
weight by converting a five layer parabolic spring to a four leaf spring by increasing
thickness of main leaf. Difference of only 13 MPa was found between the design
iterations with appreciable reduction in weight of the spring.
Vinkel Arora et al. [16] attempted to determine the effects of eye end design on a
conventional 65Si7 mono leaf spring using CAE analysis under similar loading
condition. The eyes used in the analysis were standard and casted eyes and results in
form of equivalent stresses and deformation plots were compared with experimental
results in order to propose a cost effective design. The equivalent stresses were
decreased in casted eye end design but deformation values found to be increased.
Decrease of 13% in factor of safety in casted eye end design lead to rejection of casted
eye end for the design used.
Jayanaidu et al. [17] presented the comparison of standard, inverted and centered eye
end designs of a mono leaf spring using 65Si7 and Titanium material under similar
loading conditions. The modelling of the study was done in Pro-E and analysis was
carried out using ANSYS and results were presented in the form of total deformation
and Von-Mises stress plots.
Y.S. Kong et al. [18] studied the fatigue life of a parabolic leaf spring under variable
amplitude loading (VAL). VAL includes the occasional severe events which occur

24

during actual driving conditions. VAL data was collected from three different road
conditions i.e. smooth highway, curvy road and rough road. Strain life approach using
Morrow and Smith Watson Topper (SWT) strain model was applied for fatigue life
estimation. Elastic plastic material, SAE 5160 was used in the study. FE analysis was
carried out at full load conditions with appropriate boundary conditions using
Hyperworks to obtain the stress and displacement plots. 8 noded hexa elements is used
to mesh the 3D model of the spring and nonlinear implicit quasi static time integration
scheme was used to perform analysis. Effects of large deformation and friction were
taken in account. VAL data was noted experimentally and also the load deflection rate
was determined which was having a variation of 4.7 % with the FE results. For Fe based
fatigue simulation n-Code Design Life was used and VAL data and FE analysis data at
fully loaded condition was input and results were evaluated. Based on these rough road
condition leads to highest damage and minimum fatigue life followed by curve road
and smooth highway road.

2.2 Gaps in Literature

It can be concluded from the study that leaf springs are one of the crucial members of
the automotive suspension systems and increasing need for comfort conditions, weight
reduction and increased performance have forced to optimize the design of
conventional multi leaf spring. Recent advances in leaf spring technology to cater the
above needs has led to development of parabolic leaf springs. These springs have
advantages in terms of low ride height and appreciable reduction in the mass owing to
reduced number of leaves and no to minimum interleaf friction.
Analytical design for parabolic leaf spring is cumbersome and has its limitations in
form of assumptions thereby deviating results from the actual results and thus one is

25

largely dependent on the experimental analysis. Repeated experiments thus need to be

carried out which is economically not feasible and also time taking. Recent
developments in the computer based tools in last two decades had put a great impact on
the product development and lead design time. Especially, the areas of computer aided
design (CAD) [32], led to change in the best practices followed by the design industry.
Development of computers, productivity, and design CAE tools like analysis and
simulation has led to development of new engineering disciplines.
Among the tools for design of mechanical systems, computer aided simulation
techniques for complex mechanical systems, structure analysis [33] have large say in
product development. Structure analysis simulations is used to reduce the need of
experimental validation for each design iterations and leads to tremendous saving in
development cost and lead design time. Hence CAE tools are used nowadays widely in
the automotive industries.
It also enables designers to carry out modifications, changing of material properties,
analyzing design in different environment etc. with minimum experimentation. CAE
techniques also leads to appreciable reduction in the design lead time which is of prime
importance in modern times to bring new products.
There have been many advances in the CAE tools but still they have their limitations in
determination of proper assumptions corresponding to the physics of the problem.
Other limitations lies in the software capabilities, user knowledge, and quality mesh
generation etc. Hence the validation of final result is to be carried out by the physical
testing.

26

Although every effort has been made to understand the static, contact and fatigue
behavior of multi leaf springs and three to four layer parabolic leaf spring still no work
has been reported till date on four layer parabolic leaf spring with included z bending
details in main leaf. Z-bending in leaf spring being a very new concept in leaf spring
technology is yet to be developed fully. Hence R&D efforts in this direction are being
carried out nowadays.

2.3 Problem Formulation and Statement

Leaf springs are oldest members of suspension and latest technology in these are
parabolic leaf spring which is the component of study in current work. It is having four
leaves including one leaf and three supporting leaves. All these leaves have
parabolically varying thickness from center to end and are regarded as uniform stress
leaves because of this profile. Z bending details are included in main leaf, third leaf and
fourth leaf.
3D CAD models are generated for reinforced and military wrapper eye and FE static
structure analysis is carried out on both type of eye ends in order to understand the static
capabilities of these springs under different sets of loading conditions. Four type of
loading is used and results in the form of total deflection and equivalent stresses is
calculated using ANSYS. The FEA results of reinforced eye end are compared with the
experimental results in order to validate the design and analysis procedure. Appropriate
design changes in the eye of reinforced eye end are carried out to generate military
wrapper eye and then FE analysis of that is carried out to understand its static behavior
under same loading conditions and boundary conditions.

27

CHAPTER III: METHODOLOGY

3.1 Parametric CAD Modelling
3D CAD modeling is the primary step of the CAE. It is regarded as one of the most
important step and is most time consuming also. Final result of CAD modelling is the
virtual prototype which is employed for further simulation analysis. The generated 3D
models are also suitable for visualization of the design and revision of design at later
stage in the design process.
The model of the parabolic leaf spring used in the current study is generated by using
CAD tool Solidworks. It is a complex assembly of total 11 parts including four leaves
of a four layer parabolic spring, interleaf liners, and fasteners. The 3D solid modelling
can be summarized in two major steps [34]:
1. Part modelling
2. Assembly modelling
The 3D solid models of each individual parts is generated as per the dimensions given
in 2D drawing as shown in Figure 12 and then each individual part is assembled to get
the complete assembly of the parabolic leaf spring with reinforced eye end as shown in
Figure 15. As per the drawing the bill of materials is given as in Figure 13. The 3D
solid model of leaf spring with military wrapper eye is also generated with appropriate
changes in the eye design of reinforced eye leaf spring. 3D model for military wrapper
eye can be seen in the Figure 16.

28

Figure 12: 2D drawing of the parabolic leaf spring

Figure 13: Bill of Materials

3.1.1 Part Modelling

Part modelling is the basic building block of any large scale design. Features are the
individual shapes which when combined leads to a part. 3D part section enables one to
edit features by editing the definition, sketch, or the properties of a feature, view the
parent and child relationship in the tree formed, can move or resize the features, control
to access of dimensions and changing the order in which features are constructed or roll
back the part to state it was before. One sketching is complete part modelling facilitates
feature preview in the features such as extrude, ribs, drafts etc. These are employed to
add thickness as per requirements and finally after previews are accepted to form 3D
29

solid models of parts. Defeature, dragging and copying of features is also possible
through various options in the software. Part modeling of main leaf and second leaf
used in assembly is shown as in Figure 14.

Figure 14: Part modelling of main and second leaf of parabolic leaf spring

3.1.2 Assembly Modelling

Complex assemblies consisting of many components, which can be parts or other
assemblies, called subassemblies can be created in the assembly module. Adding a
component to an assembly creates a link between the assembly and the component.
When SolidWorks opens the assembly, it finds the component file to show it in the
assembly. Changes in the component are automatically reflected in the assembly.
Important features of the assembly modeling includes
1. Feature manager design tree which shows top-level assembly (the first item),
various folders such as annotations and mates, assembly planes and origin,
components (subassemblies and individual parts), assembly features (cuts or
holes) and component patterns.
2. Basic component operations for adding, editing, deleting etc. operations for the
components in the assembly.
30

3. Design methods i.e. one can create assemblies using bottom-up design, topdown design, or a combination of both methods.
4. Mates which create geometric relationships between assembly components. As
mates are added, one define the allowable directions of linear or rotational
motion of the components. Components can be moved within their degrees of
freedom to facilitate visualizing of the assembly's behavior.
5. Other features of subassemblies, detection of problem in assemblies and
exploded views are also present.
Assembly model of both eye ends can be seen in Figure 15 and Figure 16.

Figure 15: Assembly model of parabolic leaf spring with reinforced eye end

3.2 CAE Static Structure Analysis using ANSYS WB

Static structure analysis is used to determine the displacements, stresses, strains in a
part or assembly based on material, constraints and loads applied in the form of
boundary conditions. Static analysis doesnt include the significant inertia loads and
damping loads and calculates the effects under static conditions. Static structure

31

analysis (in ANSYS WB) can be performed by using ANSYS, ABAQUS or Samcef
solvers depending upon the problem statement.

Figure 16: Assembly model of parabolic leaf spring with military wrapper eye end
A static analysis can be either linear or nonlinear. All types of nonlinearities are allowed
- large deformations, plasticity, creep, stress stiffening, contact (gap) elements,
hyperelastic elements, and so on. ANSYS utilizes basic finite element methods (FEM)
for static analysis given as
[k] {u} = {F}
Where k represents the global stiffness matrix, u represents deformation vector,
response to be determined and F represents load vector or external forces vector applied
to the structure. Certain assumptions which are followed in static structure analysis are:
1. Material behavior has to be linear elastic.
2. Small deformation theory used i.e. effects of large deformation are neglected.
3. Load applied statically. No damping or time varying forces.

32

Initial step to start analysis is the CAD model import. 3D model of assembly of
parabolic leaf spring is imported into ANSYS Workbench. Solid models for both eye
ends are as shown in Figure 17 and Figure 18 respectively. There are three basic stages
of the practical FEA i.e. Pre-Processing, Solution and Post processing [35, 36]. PreProcessing includes the material data definition, geometry, contact definition, meshing,
and application of boundary conditions (loads and constraints). After solution results
are displayed in Post-Processor which includes Equivalent Von Mises stresses and
Maximum Displacement. Various steps in FEA are described as below.

Figure 17: CAD geometry imported to ANSYS for reinforced eye end

Figure 18: CAD geometry imported to ANSYS for military wrapper eye end
33

3.2.1 Material Definition

The selection of material is one of the most important step in the spring design and is
based on the application of the spring and affects the quality and cost in large manner.
More precise selection is based on the conditions in which spring is going to be used,
load, deflection or fatigue life requirements, material grades and their availability and
hardenability requirements. The spring steel grade used in this study is JIS SUP 11A, a
spring steel grade which is Boron treated. Material used in the liners is Grey Cast Iron
and material used for Caster plate and Centre Bolt is Steel which can be seen from the
bill of materials also given in Figure 13. The material definition for both type of eye
ends is same and is defined as new material in the material library of ANSYS WB. The
various mechanical properties of SUP 11A are as shown in Table 1.
Table 1: Material properties of SUP 11A
Property

Value

Material selected
Youngs Modulus, E
Poissons Ratio

JIS SUP11A
2e5 MPa
0.29

BHN
Tensile strength Ultimate
Tensile strength Yield
Density

415-461
1272 MPa
1145 MPa
7.7e-6 kg mm^-3

Behavior

Isotropic

3.2.2 Geometry
CAD model imported in the ANSYS is displayed with details of the geometry in the
outline window on the extreme left side of the workbench window. All individual parts
of the assembly can be seen here. On selecting a part, details associated to it i.e. graphic
properties in which color visibility of individual part can be changed, definition details
to change the behavior to flexible or rigid, material assignment for each individual part.
It also shows the details of dimensions, various properties such as mass, volume,

34

centroids and moment of inertia. Material assignment of each part in assembly has to
be done individually by selecting appropriate materials from drop down menu or
material library. Meshing details i.e. number of nodes and elements are also displayed
however numeric values in these can be seen only once the model is meshed.
Geometry imported can be edited in ANSYS Design Modeler. In the current study a
feature of face split is used to define seat length region in the parabolic leaf spring. A
seat length region is regarded as no action region as if it acts as rigid. The inaction of
seat length region is due to the U clamp with which leaf spring is clamped to the axle
of the automobile. To define face split first a sketch is generated as per the required
dimensions on the required plane. Face split feature can be evoked by selecting the
newly created plane. The required dimensions depend upon the seat length which could
be of maximum value equal to 0.9 times the length of the interleaf liners [30].

3.2.3 Contact Definition

The contact definition is next step after geometry and material definitions and is very
vital in order to converge to a meaningful result. Without contact different parts in
assembly wont interact when loaded i.e. load transfer will not take place. Contact
elements can be visualized as a skin covering the region where contact occurs. ANSYS
Workbench generates contacts automatically between two bodies upon importing the
CAD file, whenever there is a contact detected between them. Contacts can also be
defined manually in connections branch given in outline window. Automatic contact is
detected by very efficient contact algorithms which works on simple principle of
proximity. If two parts are in close proximity ranges, of defined range value, they are
assumed to be in contact.

35

ANSYS automatically detects a bonded type contact which has zero degree of freedom
and behaves as a welded joint or glued part. They have surfaces fixed to each other so
that no gap can open between them and no sliding takes place. In the current study
instead of bonded joint type of contact (between two leaves or between leaf and liner)
no separation type of contact is used. No separation contacts also leads to no gaps but
it allows tangential frictionless sliding between leafs and between leafs and liners. Both
bonded and no separation contact are regarded as linear contact as only one iteration is
used to converge to result unlike frictionless, rough and frictional contacts which are
highly nonlinear and requires multiple iterations.
All other automatically generated contacts are taken as bonded only and in bonded
contacts. The contact definitions applies to face segments and care must be taken in
selecting a specific region especially near the eye. Too large contact gap can lead to
divergence. The 3D elements at contact region defined here are CONTA 174 (to define
contact) and TARGE 170 (to define target). The contact definitions for reinforced and
military eye end remains same and can be seen in Figure 19 and Figure 20 respectively.

Figure 19: Contact definition in reinforced eye end parabolic leaf spring

36

Figure 20: Contact definition in military wrapper eye end parabolic leaf spring

3.2.4 Meshing
Any continuous object has infinite degree of freedom based on the basics of continuum
mechanics, which makes the analysis impossible to be carried out and hence meshing
is carried out. Meshing is a process of reducing the infinite degree of freedom to a finite
degree of freedom problem thereby leading to solution of the analysis. SOLID187
tetrahedron element, a 3D 10-node element having quadratic displacement behavior
with three degree of freedom at each node i.e. displacements in x, y and z directions
taken in the analysis. SOLID 187 has capabilities of irregular modelling meshes. Global
meshing controls are used in both models of parabolic leaf spring which applies to the
whole assembly instead of local meshing controls. Mesh sizing options include
advanced size function on curvature, relevance center as fine, smoothing as high and
transition as slow. Total number of elements generated is 28747 for reinforced eye end
and 19500 for military wrapper eye end. Meshed models for both eye ends are seen in
Figure 21 and Figure 22.

37

Figure 21: Meshed 3D model for reinforced eye end

Figure 22: Meshed 3D model for military wrapper eye end

3.2.5 Boundary Conditions

Boundary conditions include loading and constraints in the form of force, pressure,
supports and other conditions to carry out the analysis. Boundary condition application
is one of the most critical step in pre-processing stage in order to carry out CAE
analysis. In current study the spring is modelled in flat condition, which is the maximum
deflection position in actual loading and load applied such that spring deflects to initial
position. The total load is divided on front and rear eye pin of the master leaf and fixed
support is applied on seat length (on main leaf and caster plate at bottom) and center
bolt.
38

Force is the boundary condition which could be applied to nodes, vertices, edges or
surface. Care must be taken in applying the force boundary condition to scoped
geometry. Force is evenly distributed on all entities i.e. if multiple surfaces are scoped
force would be evenly distributed on all. In current study force boundary condition is
thus applied individually to each surface of eye end. Four different magnitude of forces
are applied in order to analyze the model in four design conditions.

Figure 23: Boundary conditions applied to reinforced eye end

Figure 24: Boundary conditions applied to military wrapper eye end

39

A fixed support boundary condition constraints all the degree of freedom on vertex,
edges or surface. In current study fixed support is applied to surface. The boundary
conditions applied to the model can be seen in Figure 23 and Figure 24 respectively.

3.2.6 Solution
Static structural analysis is a part of the solution stage of FEA and aims at getting the
output as numerical values of the Von-Mises stresses and the displacement under the
application of the boundary conditions. Steady state conditions are assumed for loading
with respect to time. Analysis is performed for the pre-processed information including
material properties, loading details, supports conditions and contact definitions.

40

CHAPTER IV: RESULTS AND DISCUSSIONS

The results as obtained from the analysis of reinforced and military wrapper eye ends
are analyzed in the detailed information. Von-Mises stresses and displacement contours
have been obtained under four sets of loading conditions i.e. specified load of 4905 N,
unladen load of 12645 N, laden load of 15696 N and 2G load of 31392 N which is the
maximum load for a loaded condition, g being the design load. Analysis results for both
eye ends is obtained by static structure analysis under similar conditions.

4.1 FEA Results of Reinforced Eye End Parabolic Leaf Spring

Detailed results and discussions for reinforced eye end parabolic leaf spring are
discussed here.
Deformation at specified load (4905 N) applied on the eye ends is shown in Figure 25.
Maximum deformation is found at the eye ends (as seen in red color) and minimum
deformation in the seat length region as expected. Figure 26 shows the Equivalent VonMises contour for the specified loading. Maximum value is observed near the end of
leaf length (as seen in red color) and minimum at the seat length as expected. The
maximum deformation is found to be 22.41 mm with percentage deviation of 2.69 %
from actual results and maximum stress is found to be 174.2 MPa which is well below
the yield stress.
Figure 27 shows the deformation at unladen load (12645 N) applied on the eye end.
Maximum deformation is found at the spring eye ends (as seen in red color) and
minimum deformation in the seat length region as expected. Figure 28 shows the
Equivalent Von-Mises stresses for the unladen loading. Maximum value is observed
near the end of leaf length and minimum at the seat length. The maximum deformation

41

is found to be 55.19 mm having percentage deviation of 6.46 % from experimental

results and maximum stress is found to be 449.09 MPa much below yield stress value.

Figure 25: Deflection at specified load for reinforced eye end

Figure 26: Equivalent stresses at specified load for reinforced eye end

42

Figure 27: Deflection at unladen load for reinforced eye end

Figure 28: Equivalent stresses at unladen load for reinforced eye end
Figure 29 shows the deformation at laden load (15696 N) applied on the spring eye end.
Maximum deformation is found at the eye ends (as seen in red color) and minimum
deformation in the seat length region as expected. Figure 30 shows the Equivalent VonMises contour for the laden loading. Maximum value is observed near the end of leaf
length and minimum at the seat length. The maximum deformation is found to be 68.5
mm having percentage deviation from experimental results of 7.42 % and maximum
stress is below the yield stress value and is having magnitude of 557.45 MPa.

43

Figure 29: Deflection at laden load for reinforced eye end

Figure 30: Equivalent stresses at laden load for reinforced eye end
Total deformation at 2G load (31392 N) applied on the eye end is shown in Figure 31.
Maximum deformation is found at the eye ends and minimum deformation in the seat
length region as expected. Equivalent Von-Mises contour for the 2G load is shown in
Figure 32. Maximum value is observed near the end of leaf length and minimum at the
seat length. The maximum deformation is found to be 137.03 mm with 6.78 %
percentage deviation from actual results and maximum stress is found to be 1115 MPa
which is much below the yield stress of the material.

44

Figure 31: Deflection at 2G load for reinforced eye end

Figure 32: Equivalent stresses at 2G load for reinforced eye end

4.1.1 Experimental Load Deflection Curve for Reinforced Eye End

Experimental results for reinforced eye end are considered to validate the design and
analysis procedure of CAE analysis using ANSYS. These results are obtained by
experiments under static loading conditions assuming linear steady sate behavior and
plotted as load vs deflection curve. In addition to this load deflection rate is also given
for stiffness comparisons. These results are as shown in Figure 33

45

Figure 33: Experimental results of load vs deflection for reinforced eye end

4.1.2 Comparison of FEA Load Deflection Curve and Experimental

Load Deflection Curve
Figure 34 shows load deflection curve for the CAE results and the experimental results.
In both cases a linear relation is seen between the load and deflection under given
loading condition. Both curves are straight hence validating the CAE results.

Figure 34: Comparison between CAE and experimental load deflection curve

46

4.2 FEA Results of Military Wrapper Eye Parabolic Leaf Spring

The results of design and analysis procedure Detailed results and discussions for
military wrapper eye end parabolic leaf spring are discussed here.
Figure 35 depicts the deformation at specified load of 4905 N for the military eye end
designs. Maximum value of deformation is found to be at the eye end and minimum
value is found at seat length as per the loading condition applied. Maximum total
deformation (shown in red color) in military wrapper is 21.15 mm. Figure 36 shows the
equivalent Von-Mises plots at specified load. Maximum value of stress in military end
design is 174.92 MPa. Maximum value is found near the leaf length ends and is below
material yield stress value.

Figure 35: Deflection at specified load for military wrapper eye end
Figure 37 shows deformation plot of military eye ends at unladen load of 12645 N.
Maximum deformation of 54.52 mm in case of military wrapper eye, is found at spring
ends and minimum total deformation is found in seat length region as predicted.
Equivalent Von-Mises contour plot is as shown in Figure 38. In military wrapper eye
this value is found to be 450.94 MPa present in same region as in reinforced eye.

47

Figure 36: Equivalent stresses at specified load for military wrapper eye end

Figure 37: Deflection at unladen load for military wrapper eye end

Figure 38: Equivalent stresses at unladen load for military wrapper eye end

48

Total deformation plot for military wrapper eye under similar loading condition of
laden load having force value of 15696 N is shown in Figure 39. Maximum deformation
found at eye ends and is having value of 67.68 mm. The maximum total deformation is
found to be in accordance with the applied load and minimum deformation is found at
the seat length region. Stress contour plot of military wrapper eye is as shown in Figure
40. Maximum stress is much below the yield stress values and is found maximum near
the ends and minimum values at seat length region. Maximum stress in military eye is
having value of 559.74 MPa.

Figure 39: Deflection at laden load for military wrapper eye end

Figure 40: Equivalent stresses at laden load for military wrapper eye end

49

Maximum deformation in case of military wrapper eye at 2G load of 31392 N is shown

in Figure 41. Maximum deformation value of 135.36 mm as shown in red color at spring
eye ends is predicted by FEA analysis for military wrapper eye. Minimum value is
found at seat length region in accord with boundary conditions applied. Maximum
equivalent Von-Mises stresses is shown in Figure 42 and in military wrapper its
magnitude is 1119.5 MPa as shown in red color. Maximum stress value being less than
material yield stress thereby validates the designs and analysis. It is seen near ends and
minimum values at seat length regions as the result of constraints and loading.

Figure 41: Deflection at 2G load for military wrapper eye end

Figure 42: Equivalent stresses at 2G load for military wrapper eye end

50

4.2.1 Comparison of FEA results for Reinforced and Military

wrapper eye
Table 2 shown below gives the comparison of FEA results for the reinforced eye and
military wrapper eye for the four sets of loading applied. The Von-Mises stresses and
total deformation is almost same for reinforced and military eye. These results are in
line with the SAE manual for leaf spring [30]. Deformation is slightly lower in military
eye because of high stiffness and Von-Mises stresses are slightly more but well below
the material yield stress value. The military eye is mostly preferred in heavy duty
applications where high safety margins are required.
Table 2: Comparison of FEA results for Reinforced and Military wrapper eye
Reinforced Eye
Military wrapper eye
Load set
Load Deflection
Equivalent
Deflection
Equivalent
(N)
(mm)
Von-Mises
(mm)
Von-Mises
Stress (MPa)
Stress (MPa)
Specified
4905 21.41
174.2
21.15
174.92
load
Unladen
12645 55.19
449.09
54.52
450.94
load
Laden load 15696 68.50
557.45
67.68
559.74
2G load
31392 137.03
1115
135.36
1119.5

51

CHAPTER V: CONCLUSION
From the results obtained from the FEA analysis and on comparison with experimental
results following conclusion have been made in the current study:
1. The load deflection curve as calculated from finite element analysis for
Reinforced eye end is found to be linear and in accordance with the
experimental load deflection curve. The CAE load rate is 23.35 Kgf/mm, a
variation of 7.6 % is observed from actual rate value (21.587% Kgf/mm).
2. Maximum total deformation in Reinforced eye is found to be 137.03 mm under
2G load and maximum equivalent Von-Mises stress is 1115 MPa which is well
below the yield stress (1196 MPa) indicating safe design. Maximum stress
concentration is found near end of the leaf length probably developed because
of change in thickness and geometry.
3. Variation in total deformation under all type of loading in Reinforced eye is
found to be 2.7 to 7.4 % with respect to experimental load deflection curve
which is acceptable and hence the analysis stands validated.
4. Von-Mises stresses and total deformation for Reinforced and Military wrapper
eye are found to be almost the same.
5. Military wrapper eye results in stiffer and safer design and ability of the wrapper
on second leaf to be used as an eye in case of failure of main leaf eye. Military
wrapper eyes are hence recommended for use in heavy loading application.

52

CHAPTER VI: FUTURE SCOPE

1. The design has to be optimized further in order to reduce the maximum
equivalent Von-Mises stresses as they are near to yield stresses in case of 2G
loading (maximum load conditions).
2. Fatigue analysis can also be carried out to validate the fatigue life cycles
requirements. This can be done by FE analysis by employing CAE tools and
validation of the same by experimental techniques.

53

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55

Appendix A
List of Publications
1. Ishan Aggarwal, Gian Bhushan, Pankaj Chandna, Static Structure Analysis
of SUP11A Multi Leaf Symmetrical Parabolic Leaf Spring, International
Bulletin of Mathematical Research, ISSN: 2394-7802, Vol. 2 (1), 2015, pp. 229225.
2. Ishan Aggarwal, Gian Bhushan, Pankaj Chandna, Linear Static Structure
Analysis of Military Eye and Reinforced Eye Ends of Parabolic Leaf
Spring, Proceedings of the 5th National Conference on Recent Advances in
Manufacturing, 2015, ISBN: 978-93-5212-649-1, pp. 308-313

56