Structural Analysis and Topology Optimization of Leaf Spring Bracket
Shraddha R. Gunjawate, Shrishail B. Solapur
Abstract
Leaf spring is a basic form of suspension, widely used in commercial vehicles like tempo, truck etc . It is made up of layers of long steel plates of varying lengths, sandwiched one upon the other. Leaf spring is attached to chassis with the help of leaf spring mounting bracket. Shape and size of the bracket differs from vehicle to vehicle. As bracket acts as a link between chassis and suspension, it can be redesigned in optimum manner, such that it will have low weight and can efficiently transfer stresses without failure. In this paper, we have done weight optimization of leaf spring bracket of LCV Diesel truck, using Topology optimization method. Leaf spring bracket is modeled using CREO 2.0 software. Real condition forces and constrains are applied on bracket. Static and fatigue analysis is done using Ansys software. Topology optimization of leaf spring bracket is done in Ansys 19. Final optimized bracket is redesigned as per result generated by topology optimization in Ansys and manufacturing feasibility. Static and fatigue analysis is carried out on an optimized bracket design. It is observed that stress value in original and optimized bracket remains same. Strain gauge testing is conducted on optimized bracket. Strain value measured on strain gauge at 6000N load is 153.2 microstrain and strain value measured in FEA at same load and location of strain gauge is 180 microstrain. Weight of the bracket is reduced from 1.8Kg to 1.6 Kg i.e. 200 grams, which is equal to 12% of original bracket weight. Hence, Weight optimization of Leaf spring bracket is done using Topology optimization method, without degrading the bracket performance with respect to original bracket design.