FEA ANALYSIS AND PERFORMANCE TESTING OF MASTER LEAF

MECHANICAL DESIGN ENGG.

The subject gives a brief look on the suitability of steel leaf spring on vehicles and their advantages. Efforts have been made to find out stress- strain analysis of a leaf spring with varying load. The achievement of weight reduction with adequate improvement of mechanical properties has made steel a very replacement material for convectional steel. Material and manufacturing process are selected upon on the cost and strength factor. The design method is selected on the basis of mass production. The Automobile Industry has shown interest in steel leaf spring since the steel material has high strength to weight ratio good corrosion resistance and mechanical properties. The experiments will be conducted on Universal Testing Machine and numerical analysis was done via (FEA) using ANSYS 14.0 software. Stresses and deflection results were verified for analytical and experimental results. In this work the origin of premature fracture in leaf springs. To this end common failure analysis procedures including examining the leaf spring history visual inspection of fractured specimen’s characterization of various properties and simulation tests on real components were used. It is concluded that fracture occurred by a mechanism of mechanical fatigue initiated at the region of the central hole which suffered the highest tensile stress levels. Several factors (poor design, low quality material and defected fabrication) have combined to facilitate failure.

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