Experimental and finite element analysis of different types of leaf springs for automotive applications

This study presents an in-depth experimental and finite element analysis (FEA) of leaf springs with varying geometries. Three distinct configurations—cantilever, semi-elliptical, and double-set multi-leaf springs—were examined using three different materials: Aluminium alloy, structural steel, and glass fiber-reinforced polymer (GFRP) composites. The 3D modeling of each design was performed using CATIA, and structural simulations were conducted via ANSYS Workbench. The FEA results were subsequently validated against both experimental data and theoretical predictions. Computational findings revealed that the double-set multi-leaf spring configuration exhibited superior structural integrity, characterized by significantly reduced deformation and stress levels compared to the other designs. This enhanced performance underscores its suitability for medium to heavy-duty automotive suspension systems, offering improved load-bearing capacity, ride comfort, and extended operational lifespan. Under a centrally applied load of 10,000 N, the cantilever, semi-elliptical, and double-set multi-leaf springs fabricated from structural steel exhibited deformations of 3.61 mm, 0.014 mm, and 0.0062 mm, respectively. For the semi-elliptical configuration under identical loading conditions, the theoretical, experimental, and FEA results yielded deformations of 0.015 mm, 0.014 mm, and 0.0142 mm, respectively. Although, the semi-elliptical design remains prevalent in current applications, it was found to experience higher stress and greater deformation. In contrast, the double-set elliptical design demonstrated a more favorable balance of compactness and mechanical performance, marked by substantially lower stress and deformation levels. Cantilever leaf spring gave higher deflection & stress semi-elliptical & double type. GFRP exhibited higher deformation & FOS compared to steel and Aluminium. Experimentation of leaf spring yielded a deformation of 0.014 mm & stress of 8.8 MPa. The deformation & FOS by FEA & theoretical analysis exceeded experimental results.