Replacement of Conventional Material by Composite Materials Considering Variable Loads

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1 Volume-5, Issue-3, June-2015 International Journal of Engineering and Management Research Page Number: Replacement of Conventional Material by Composite Materials Considering Variable Loads Bipin H M 1, Dr. Mohamed Haneef 2, Mohammed Imran 3 1 PG student, M-Tech 4 th Semester, Machine Design, Department of Mechanical Engineering, Ghousia College of Engineering, Ramanagaram, INDIA 2 Professor and Principal, Department of Mechanical Engineering, Ghousia College of Engineering, Ramanagaram, INDIA 3 Assistant Professor, Department of Mechanical Engineering, Ghousia College of Engineering, Ramanagaram, INDIA ABSTRACT Safety of the structure is the most important factor in each and every part of the automobile. dynamic loads will be considered to find the damage of the material. Leaf spring is the one of the most important part in the automobile field, for the better suspension system in automobile vehicles parts used are leaf springs and shock absorbers. The main function of leaf spring is not only to support vertical load but also to isolate road induced vibrations. It is subjected to millions of load cycles leading to fatigue failure. In the present work Al6061 and Az91cMg materials were used to find the stiffness and Number of cycles to failure, the results were discussed and tabulated. Keywords Leaf spring, Stiffness, Catia, Number of cycles to failure I. INTRODUCTION The major of the automobile structures has been failed due to repeated loads. Fatigue leads an important path for the finding the structural damages and need to be calculate the Factor of safety Stiffness and Failure cycles were considerable parameters. To conserve and utilizing properly the natural resources and proper from of energy weight reduction has been the main thing for automobile sectors in current situation it can be achieved initially by taking the good material proper design optimization and better manufacturing process one of the most effective potential items for weight reduction is the suspension leaf spring. The most important field of the automobile is a suspension system in which many of the researches has been carried out thoroughly based on the comfort requirements. Some of the papers has been mentioned that the different loading conditions of conventional material as well as other composite materials [3] [5] Some of the papers were given the Calculations, Proper standard designing and Formulae were be considered [1] [2]. II. METHODOLOGY Analysis of problems studied by the various literature surveys. Standard dimensions and boundary conditions were considered as per ASME Using Catia software Modeling and meshing of a leaf spring has been made. Using ANSYS, apply the boundary condition to the model of a leaf spring so that the stresses and displacements were found and calculated the Stiffness and failure cycles. A. Geometric parameters i. Design of a mono leaf spring and its specifications 509 Copyright Vandana Publications. All Rights Reserved.

2 iii. Boundary condition Fig.3. Boundary conditions of a leaf spring Fig.1. 2d model of a mono leaf spring The specifications all are represented in the fig.1, such that the thickness is considered as 10 mm for a mono leaf spring. Variable load is varied from 2000 to 6000N at the time variation of 10 seconds. Boundary condition applied for leaf spring fixed in all directions and loaded centrally, cyclic loads were applied with varying time. B. Material properties Table I Represents the material properties ii. Meshed model of a mono leaf spring III. RESULTS AND DISCUSSION Results 1. Analytical Results For cyclic load A. For Al6061 material Stress analysis Fig. 2. Meshed model of a leaf spring 510 Copyright Vandana Publications. All Rights Reserved.

3 Fig.4 Stress analysis for 2000N at 5sec Fig.7 Displacement analysis for 2000N at 5sec Fig.8 Displacement analysis for 4000N at 15sec Fig.5 Stress analysis for 4000N at 15sec Fig.6 Stress analysis for 6000N at 25sec Displacement analysis Fig.9 Displacement analysis for 6000N at 25sec B. Az91cMg Material Stress analysis 511 Copyright Vandana Publications. All Rights Reserved.

4 Fig.10 Stress analysis for 2000N at 5sec Fig.13 Displacement analysis for 2000N at 5sec Fig.11 Stress analysis for 4000N at 15sec Fig.14 Displacement analysis for 4000N at 15sec Fig.15 Displacement analysis for 6000N at 25sec Fig.12 Stress analysis for 6000N at 25sec C. Theoretical result Table II Represents the Stiffness and displacement values 512 Copyright Vandana Publications. All Rights Reserved.

5 The number of cycles to failure in Al606 and Az91cMg both the materials were having more than 10 5 cycles, which is more than the Steel material. Hence concluding that the composite material Al6061 is better replacement material instead of steel material in all the considered parameters for a mono leaf spring. REFERENCES Number of cycles to failure Considering the loading condition as 2000N such that Ultimate strength of the Al6061 material is 910Mpa and Sa=160.46, Ultimate strength of the Az91cMg material is 845 and Sa= By using the formula [2], N f has been calculated. The value of N f of Al6061is X 10 6 cycles and Az91cMg is 4.7 X 10 6 cycles Discussions Table III Represents correlating results table From Table III. represents the comparison of deflections in both Al6061 and Az91cMg materials. The Stiffness of the Al6061 material for Analytical and theoretical values are and N/mm respectively and for the Az91cMg material the Stiffness values are and N/mm. By comparing all these stiffness values by the 2 different materials whereas the steel material would have less stiffness values with the same loading conditions because of lower Elastic modulus. V. CONCLUSION Comparative study has been made between Al6061l and the Az91cMg material with respect to stress and deformation analytically and theoretically to find the Stiffness and failure cycles. While comparing the stiffness the A6061 amdaz91cmg materials were stiffer than steel in Analytical as well as Theoretical manner. [1] Mahmud M. Shokrieh, Davood Rezaei, Analysis and optimization of a composite leaf spring, Composite Structures 2003(60), pp [2] Seyyedvahid Mortazavian, Ali Fatemi Fatigue behavior and modeling of short fiber reinforced polymer composites Elsevier International journal of Fatigue 70(2015) [3] Baviskar A. C., Bhamre V. G., Sarode S. S. Design and Analysis of a Leaf Spring for automobile suspension system: A Review International Journal of Emerging Technology and Advanced Engineering Website: (ISSN , ISO 9001:2008 Certified Journal, Volume 3, Issue 6, June 2013) [4] Al-Qureshi H A (2001), Automobile leafsprings from composite materials, Journal of Materials Processing Technology, 118(2001) pp [5] V. Pozhilarasu,Dr. T. Parameswaran Pillai, Performance Comparison of convention and composite leaf spring, International Journal of Engineering science and Technology, ISSN [6] Pankaj Saini, Ashish Goel, Dushyant Kumar Design and analysis of composite leaf spring for light vehicle International Journal of Innovative Research in Science, Engineering and Technology ISSN: Vol. 2, Issue 5, May [7] B.Vijaya Lakshmi, Satyanarayana,; Static and dynamic analysis on composite leaf sprig in heavy vehicle, International Journal of Advanced Engineering Research and Studies, 2012(2), pp [8] Manjunath H.N, Manjunath.K, T.Rangaswamy Static Analysis and Fatigue Life prediction of Composite Leaf Spring for alight Commercial Vehicle International Journal of Engineering Research ISSN: , Volume No.3, Issue No.7, pp : July 2014 IJER@2014 Page Copyright Vandana Publications. All Rights Reserved.