Computational study on the potential of aluminium alloy as a candidate material in automotive leaf spring

ABSTRACT

Modern advancements and emerging trends in automobile technology have shifted the primary focus of the OEMs to make vehicles lighter, faster, and reliable. Weight has always been a major concern in commercial medium/heavy-duty vehicles. The leaf springs account for 20% of the sprung weight of the vehicle thereby making the suspension system one of the heavy components of an automobile. This paper focuses on analysing the potential of aluminium alloy as a candidate material in leaf spring so as to make the suspension system lighter and more reliable. Aluminium alloy is one of the appropriate materials to proceed with because of its lightweight, strength, and non-significant deformation during load cycles. Three-dimensional CAD model of standard leaf spring was created in DS CATIA V5R19 software and computational analysis were carried out in ANSYS Workbench 18.1 by defining material as plain carbon steel (structural steel) and Aluminium alloy for comparative study. The results of the analysis that the reduction in weight of the leaf spring using aluminium alloy was approximately 64.71% along with a significant reduction in equivalent stress induced at different loading condition with a maximum reduction of 45.30% equivalent stress at the fully loaded dynamic condition.

KEYWORDS:

• Analysis
• aluminium alloy
• automotive
• leaf spring
• stress

Disclosure statement

No potential conflict of interest was reported by the authors.

Additional information

Notes on contributors

Mayank Kamboj

Mr. Mayank Kamboj is a final year engineering graduand pursuing Bachelor's in Automotive Design Engineering from University of Petroleum and Energy Studies (UPES), Dehradun. Also he is currently working as student program chairperson for UPES SAE Collegiate club and his current area of research is active utilisation of composite materials/alloy in automobiles. He is interested in Internal Combustion Engines, Thermodynamics, Heat transfer and automotive chassis components design.

Amit Chetry

Mr. Amit Chetry did his schooling from Evergreen English School and Higher Secondary study from Tezpur Science Academy. Presently he is a final year engineering undergraduate pursuing Bachelor’s of Technology in Automotive Design Engineering from University of Petroleum and Energy Studies, Dehradun. He is an active member of SAE UPES Collegiate club and have done many vehicle design projects viz. Design and fabrication of Go-kart, Quad bike and Nitro buggy. His current area of research is computational study of different alloys to serve as candidate material for IC engine components. He is interested in IC Engines, Design of Automotive Chassis Components and Fluid Mechanics.

Caneon Kurien

Dr. Caneon Kurien is working as Research Associate in Department of Energy, Tezpur University, Assam. He received a bachelor's degree in Mechanical Engineering from Calicut University and master's degree in Pipeline Engineering from University of Petroleum and Energy Studies and Ph.D. degree in Mechanical Engineering (Thermal science and engine exhaust after-treatment) from University of Petroleum and Energy Studies. His current area of research is on the development of an intuitive emission control system for IC engines, sustainable energy, electric vehicles and design of smart Bio-gas reactors. He is interested in internal combustion engines, computational fluid dynamics, energy systems and fluid transportation.

Ajay Kumar Srivastava

Dr. Ajay Kumar Srivastava is working as Professor and Head of Mechanical Engineering Department in University of Petroleum and Energy Studies. He received a bachelor's degree in Mechanical Engineering from Visweraya Technological University and Master's degree in Design of Process machines and Ph.D. degree in VARTM process modelling from Motilal Nehru National Institute of Technology, India. He is an active member of SAE (Society of Automotive Engineers) and ASHRAE (American Society of Heating, Refrigeration and Air-Conditioning Engineers) His current area of research is on the exhaust emission control of compression ignition engines and development of composite materials and composite manufacturing processes.