MULTI-LEAF SPRING USING ALUMINIUM METAL MATRIX COMPOSITES: DESIGN AND ANALYSIS

The development of lightweight and high-performance materials has become a pivotal focus in automotive engineering due to the growing demand for energy-efficient and environmentally friendly vehicles. This research focuses on the use of Aluminium Metal Matrix Composites (Al-MMCs) as substitute materials for steel in the design and improvement of leaf springs, which are vital in vehicle suspension systems. By employing CAD modelling and FEA, the mechanical behaviour of the developed Al/SiC MMC and Al/B4C MMC leaf springs are analysed and compared under different static load conditions of 12,500 N & 17,500 N. The analysis focuses on deformation, stress distribution, and weight reduction compared to conventional steel leaf springs. These outcomes indicate that Al-MMCs can achieve up to 60% weight reduction with an improvement or comparable stress-handling capacity. Among all the materials, the stiffness and lower deformation at the maximum load indicate that Al/B4C MMC is a potential material for high-performance and lightweight vehicles. This study focuses on the potential of enhancing Al-MMCs for better fuel economy and vehicle performance by using sustainable automotive material choices. The results of this research will provide possibilities for other high-risk automotive applications of composite material by explaining the behaviour and performance of the material and new designs.