TOWARDS A GREENER FUTURE: LIGHTWEIGHT COMPOSITE LEAF SPRINGS AND SUSTAINABLE VEHICLE PERFORMANCE

Abstract

Leaf springs play a crucial role in the suspension system of vehicles, absorbing shocks and loads to provide stability and support between wheels, axles, and the vehicle chassis. Their tight-knit structure enables them to withstand vertical loads and distribute them along their length with the assistance of springs and dampers. However, the concentrated force resulting from vertical flex can sometimes exceed the suspension's capacity to handle, necessitating improvements in design and materials.

This study focuses on enhancing leaf spring performance through weight reduction without compromising load-carrying capacity. Reducing unsprung weight is essential for enhancing fuel efficiency and riding qualities in automobiles. Unsprung components, including wheel assemblies, axles, and a portion of suspension springs and shock absorbers, contribute significantly to the overall unsprung weight, with leaf springs alone accounting for 10-20%.

The introduction of composite materials has provided an opportunity to decrease the unsprung mass without compromising strength or load-carrying capacity. Composite materials exhibit high elastic strain energy storage capacity and an excellent strength-to-weight ratio compared to traditional steel. Additionally, composite leaf springs demonstrate exceptional fatigue resistance and durability, outperforming their steel counterparts.

This research aims to investigate the benefits of replacing traditional steel leaf springs with composite alternatives. The analysis includes evaluating the performance of composite leaf springs in terms of stress distribution and weight reduction compared to steel springs. The results indicate that the use of composite leaf springs leads to lower stresses, enabling significant fuel savings and improved vehicle performance.