scholarly journals Design Optimization and FE Analysis of 3D Printed Carbon PEEK Based Mono Leaf Spring

Micromachines ◽  
2019 ◽  
Vol 10 (5) ◽  
pp. 279 ◽  
Author(s):  
Amir Kessentini ◽  
Gulam Mohammed Sayeed Ahmed ◽  
Jamel Madiouli
Keyword(s):  
Finite Element ◽  
Design Optimization ◽  
Polymer Composite ◽  
Material Selection ◽  
Design Parameters ◽  
Leaf Spring ◽  
Bending Stress ◽  
Leaf Springs ◽  
Percentage Volume ◽  
3D Printed

In this research work, design optimization and static analysis of a 3D printed based carbon PEEK (poly ether ether ketone, reinforced with carbon) polymer composite mono leaf spring was done using finite element analysis. Comparative study of leaf springs of a Dodge SUV car has been made by using 3D printed carbon PEEK. The main objective of this work is to optimize the design and material parameters, such as fiber diameter, fiber length, percentage volume of fibers and orientation angle of fibers in 3D printed based material with a mono polymer composite leaf spring. The effects of these parameters were studied to evaluate the deflection, bending stress, spring rate, stiffness and von Mises stress under different loading conditions. Furthermore investigation has been done to reduce the weight of leaf springs and claimed the 3D printed based leaf springs have better load carrying capacity. Thus an attempt has been made in this regard and we selected the 3D printed carbon PEEK in developing product design and material selection for minimum deflection and bending stress by means of response surface optimization methodology for an efficient leaf spring suspension system. The 3D printed carbon fiber polymer composite has three different percentage volume fractions such as 30%, 50%, and 60%. The selected carbon PEEK has 0°, 45°, and 90° fiber orientations. Finite element based analysis has been performed on 3D printed carbon PEEK material to conclude the optimized design parameters and best possible combination of factors affecting the leaf spring performance.

Thick Film Accelerometers in LTCC Technology—Design Optimization, Fabrication, and Characterization

2008 ◽  
Vol 5 (4) ◽  
pp. 150-155 ◽  
Author(s):  
Holger Neubert ◽  
Uwe Partsch ◽  
Daniel Fleischer ◽  
Mathias Gruchow ◽  
Alfred Kamusella ◽  
...  
Keyword(s):  
Design Optimization ◽  
Thick Film ◽  
Probability Distributions ◽  
Pressure Sensors ◽  
Measurement Data ◽  
Design Parameters ◽  
Optimized Design ◽  
System Failure ◽  
Functional Requirements ◽  
Leaf Springs

Diaphragms and beams for force and pressure sensors, e.g., are state of the art in mechanical elements of MEMS in LTCC technology. These elements sustain small strains and small deformations under load. A number of sensor and actuator applications, however, require movable elements that allow higher deformations while the local strains are still low. Springs, accelerometers, actuators, positioners, and valves are examples of such applications. For an accelerometer we developed an approach fabricate leaf springs, integrated into the LTCC technology. The working principle of the accelerometer is based on a seismic mass disposed on two parallel leaf springs that carry piezoresistors connected such that they form a measuring bridge. In the first design optimization step, we used an FEA model for finding an optimized design meeting our sensitivity requirements, inclusiding resonance frequency. In the second step, we made a tolerance analysis that calculates the probability distributions of functional variables from the probability distributions of the design parameters. This enables the probability of a system failure to be deduced. In a final design step, a design of the ceramic thick film accelerometer was calculated that minimizes the system failure probability. As a result we obtained a design optimized with respect to a set of functional requirements and design tolerances. The results of the computations using the FEA models were compared to results of measurement data acquired from prototypes of the accelerometer.

scholarly journals Explicit Nonlinear Finite Element Geometric Analysis of Parabolic Leaf Springs under Various Loads

2013 ◽  
Vol 2013 ◽  
pp. 1-11 ◽  
Author(s):  
Y. S. Kong ◽  
M. Z. Omar ◽  
L. B. Chua ◽  
S. Abdullah
Keyword(s):  
Finite Element ◽  
Experimental Testing ◽  
Geometric Analysis ◽  
Leaf Spring ◽  
Original Design ◽  
Fe Method ◽  
Vertical Stiffness ◽  
Emergency Braking ◽  
Leaf Springs ◽  
Load Carrying

This study describes the effects of bounce, brake, and roll behavior of a bus toward its leaf spring suspension systems. Parabolic leaf springs are designed based on vertical deflection and stress; however, loads are practically derived from various modes especially under harsh road drives or emergency braking. Parabolic leaf springs must sustain these loads without failing to ensure bus and passenger safety. In this study, the explicit nonlinear dynamic finite element (FE) method is implemented because of the complexity of experimental testing A series of load cases; namely, vertical push, wind-up, and suspension roll are introduced for the simulations. The vertical stiffness of the parabolic leaf springs is related to the vehicle load-carrying capability, whereas the wind-up stiffness is associated with vehicle braking. The roll stiffness of the parabolic leaf springs is correlated with the vehicle roll stability. To obtain a better bus performance, two new parabolic leaf spring designs are proposed and simulated. The stress level during the loadings is observed and compared with its design limit. Results indicate that the newly designed high vertical stiffness parabolic spring provides the bus a greater roll stability and a lower stress value compared with the original design. Bus safety and stability is promoted, as well as the load carrying capability.

A FRAMEWORK FOR CAPTURING DEGRADATION BEHAVIOR IN RELIABILITY-BASED ROBUST DESIGN OPTIMIZATION

2011 ◽  
Vol 18 (06) ◽  
pp. 531-554 ◽  
Author(s):  
OM PRAKASH YADAV ◽  
SUNIL S. BHAMARE ◽  
AJAY PAL SINGH RATHORE
Keyword(s):  
Design Optimization ◽  
Robust Design ◽  
Degradation Process ◽  
Development Stage ◽  
Robust Design Optimization ◽  
Design Parameters ◽  
Leaf Spring ◽  
Degradation Behavior ◽  
Multi Objective ◽  
Target Values

The increasing customer awareness and global competition have forced manufacturers to capture the entire life cycle issues during product design and development stage. The thorough understanding of product behavior (degradation process) and various uncertainties associated with product performance is paramount to produce reliable and robust design. This paper proposes a multi-objective framework for reliability-based robust design optimization, which captures degradation behavior of quality characteristics to provide optimal design parameters. The objective function of the multi-objective optimization problem is defined as quality loss function considering both desirable and undesirable deviations between target values and the actual results. The degradation behavior is captured by using empirical model to estimate amount of degradation accumulated in time t. The applicability of the proposed methodology is demonstrated by considering a leaf spring design problem.

scholarly journals Effect of Assembly Stresses on Fatigue Life of Symmetrical 65Si7 Leaf Springs

2014 ◽  
Vol 2014 ◽  
pp. 1-10
Author(s):  
Vinkel Kumar Arora ◽  
Gian Bhushan ◽  
M. L. Aggarwal
Keyword(s):  
Fatigue Life ◽  
Maximum Stress ◽  
Testing Machine ◽  
Vital Role ◽  
Design Parameters ◽  
Leaf Spring ◽  
Leaf Springs ◽  
Light Commercial Vehicle ◽  
Load Rate ◽  
Suitable Combination

The maximum stress induced plays vital role in fatigue life improvement of leaf springs. To reduce this maximum stress, leaves with different unassembled cambers are assembled by pulling against each other and a common curvature is established. This causes stress concentration or sets assembly stress in the assembled leaf springs which is subtractive from load stress in master leaf while it is additive to load stress for short leaves. By suitable combination of assembly stresses and stepping, it is possible to distribute the stress and improve the fatigue life of the leaf spring. The effect of assembly stresses on fatigue life of the leaf spring of a light commercial vehicle (LCV) has been studied. A proper combination of stepping and camber has been proposed by taking the design parameters into consideration, so that the stress in the leaves does not exceed maximum design stress. The theoretical fatigue life of the leaf springs with and without considering the assembly stresses is determined and compared with experimental life. The numbers of specimens are manufactured with proposed parameters and tested for load rate, fatigue life on a full scale leaf springs testing machine. The effect of stress range, maximum stress, and initial stress is also discussed.

Multibody System Modeling of Leaf Springs

2004 ◽  
Vol 10 (11) ◽  
pp. 1601-1638 ◽  
Author(s):  
Mohamed A. Omar ◽  
Ahmed A. Shabana ◽  
Aki Mikkola ◽  
Wei-Yi Loh ◽  
Rena Basch
Keyword(s):  
Finite Element ◽  
Absolute Nodal Coordinate Formulation ◽  
Frame Of Reference ◽  
Leaf Spring ◽  
Reference Formulation ◽  
Order Model ◽  
Reduced Order ◽  
Absolute Nodal Coordinate ◽  
Leaf Springs ◽  
Floating Frame

Leaf springs are essential elements in the suspension systems of vehicles including sport utility vehicles, trucks, and railroad vehicles. Accurate modeling of the leaf springs is necessary in evaluating ride comfort, braking performance, vibration characteristics, and stability. In order to accurately model the deformations and vibrations of the leaf springs, nonlinear finite-element procedures, which account for the dynamic coupling between different modes of displacement, are employed. Two finite-element methods that take into account the effect of the distributed inertia and elasticity are discussed in this investigation to model the dynamics of leaf springs. The first is based on a floating frame of reference formulation, while the second is an absolute nodal coordinate formulation. The floating frame of reference formulation allows for using a reduced-order model by employing component mode synthesis techniques, while the absolute nodal coordinate formulation enables more detailed finite-element models for the large deformation of very flexible leaf springs. Methods for modeling the contact and friction between the leaves of the spring are discussed. A comparison is also presented between the results obtained using the proposed method and simplified approaches presented in the literature. While there are many issues that can be important in leaf spring modeling, the analysis presented in this paper is focused on a few key issues that include the computer implementation, the effect of the dynamic load on the spring stiffness, the selection of the vibration modes in the reduced-order model, and the effect of the structural damping on the response of the leaf spring.

scholarly journals Design Optimization and Simulation Analysis of Formula SAE Frame Using Chromoly Steel

2019 ◽  
Vol 6 (2) ◽  
pp. d9-d13 ◽  
Author(s):  
M. D. Kumar ◽  
P. S., Teja ◽  
R. Krishna ◽  
M. Sreenivasan
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Design Optimization ◽  
Simulation Analysis ◽  
Material Selection ◽  
Study Data ◽  
Element Analysis ◽  
Formula Sae ◽  
Optimization And Simulation ◽  
Aisi 4130

Compliance with the rules and regulations of competition “Student Formula Car Racing” that conducted annually by the ‘Society of Automotive Engineers’ (SAE) India, the car frame must be designed and built with supreme priority. The major task posed is to design and fabricate a light weighed vehicle chassis frame without compensating the safety. This paper boards various methods of material selection, technical design optimization and Finite Element Analysis using ANSYS. The basic design is based on the anthropological study data of the specified human (95th percentile male) al-lowing fast ‘way-in’ and ‘way-out’ access from the car. According to the rules book specification on material selection, AISI 4130 chromoly steel was the first time identified for the frame design. Resulting in the final design of the vehicle frame, various analyses were done using ANSYS and the successive results are plotted and discussed. The entire design optimization and simulation analysis are based on the 2019 Formula SAE rules book. Keywords: finite element analysis, AISI 4130 chromoly steel, frame construction, Society of Automotive Engineers.

Motorcycle Swing Arm Development and Refinement Using Response Optimization

2015 ◽  
Author(s):  
Michael Sapanaro ◽  
Suhash Ghosh ◽  
Chittaranjan Sahay
Keyword(s):  
Finite Element ◽  
Central Composite Design ◽  
Design Optimization ◽  
Design Process ◽  
Material Selection ◽  
Structural Models ◽  
Design Attributes ◽  
Swing Arm ◽  
Response Optimization ◽  
Central Composite

The purpose of this project is to develop a motorcycle rear swing arm using finite element analysis and response optimization. This paper aims to discuss the specific features, benefits, and precautions when using design optimization to develop a specific project. Design Optimization has been an evolving process for many years. The latest versions of finite element software allow users to develop, analyze, and optimize structural designs within one program quickly and efficiently. A single shock absorber mounted close to the chassis and centrally located was the design selected to be analyzed. The design was selected for use in a variety of motorcycle types. This project consisted of a unique set of design attributes that were ideal to exemplify design optimization techniques. Static structural models were created to refine the design before using response optimization. These models finalized the material selection and initial sizes. A central composite design type was generated with selected boundary conditions for four parametric dimensions of the model. The ideal design of this component would include the resulting stress below a safe allowable value, minimal deflection, and the least amount of weight. It is evident that these three parameters will oppose one another as geometry is changed. Conceptually, an ideal candidate can be created that is a balance of the three parameters. Using the parameters of the selected candidate, a new model was generated for analysis. The final model was further refined by removing unnecessary material that was identified in the structural models. The first step in a thorough optimization is generating an appropriate amount of design parameter values that are an acceptable representation of all the possible outcomes, or design of experiments (DOE). The DOE tool used to generate the parameters in this project was central composite design (CCD), since it is the most appropriate for second order response models [1]. The second order relationship was confirmed using a trade-off plot. The two level, four input parameter DOE produces twenty five potential candidates that were refined using response surface. The response surface method used in this design process [2,3] to make judgement calls on the final design is examined during this development, and proves useful. Initial static structural models are created and used to set up the model for optimization. Material selection was also accomplished in this phase of development. This process aides in the overall design process by identifying areas of concern as well as the range of parameters that will be analyzed. Multiple acceptable candidates were selected through the use of the optimization tools and a final candidate was selected based on the output of the design attributes and the values of the corresponding parametric geometry. The final selection was also made with the consideration for cost, ease of fabrication, and standardization.

Probabilistic Design Optimization of Frequency Dispersion for Rotating Blades

2010 ◽  
Author(s):  
Liqiang An ◽  
G. Gary Wang ◽  
Zhangqi Wang
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Design Optimization ◽  
Optimization Problem ◽  
Frequency Dispersion ◽  
Probabilistic Constraints ◽  
Design Parameters ◽  
Probabilistic Design ◽  
Rotating Blades ◽  
Element Method

In this paper, a probabilistic design optimization method based on finite element method is proposed to calculate the variability of design parameters subject to a specified dispersion of natural frequencies of rotating blades. The element stiffness and mass matrices are derived using a two-stage finite element method and numerical integration. Based on the perturbation technology, the sensitivity of the frequencies, as well as relationship between the frequency dispersion and the coefficient of variability (CV) of the design parameters can be obtained. Such sensitivity information is then used to convert the probabilistic design optimization problem into a deterministic optimization problem. Two case studies are given to illustrate the proposed method. From the results, it is concluded that rotation of blade changes the sensitivity of CV to the design parameters considered, and using the proposed method can transform the probabilistic constraints to deterministic constraints.

Finite Element Analysis Based Design Optimization of Exciting Efficiency for Micromachined Piezoelectric Transducer

2008 ◽  
Author(s):  
Chenguang Cai ◽  
Quayle Chen ◽  
Dujuan Zeng ◽  
Fei Deng ◽  
Antti Salo ◽  
...  
Keyword(s):  
Finite Element ◽  
Design Optimization ◽  
Piezoelectric Transducer ◽  
Structural Parameters ◽  
Design Parameters ◽  
Piezoelectric Film ◽  
Element Analysis ◽  
Element Simulation ◽  
Vibration Magnitude ◽  
Design Options

This paper presents a design optimization of a membrane-based ultrasonic piezoelectric transducer using micromachining by finite element simulation. The transducer can be used to generate ultrasound using the piezoelectric film to excite the vibration of the transducer membrane. The objective is to maximize the vibration magnitude of the membrane by optimizing the structure of the transducer, when the exciting signal is fixed. The size and the shape of the piezoelectric film were selected as the design parameters to optimize the structure of the transducer. Based on the theoretical analysis, it is found that the absolute values of the stresses in the center and the boundary of the diaphragm are greater than that on the other regions of the film, with the directions of the stress on center and boundary opposite to each other. In order to achieve the maximum exciting efficiency, the discrepancy in the stresses between the center and the boundary on the diaphragm should be maximized. In this paper, totally four different piezoelectric film structures are analyzed for optimizing the exciting efficiency of the transducer. The finite element models of the transducer were created using ANSYS. The simulations based on the three design options were performed; and through the comparison of the simulation results, the optimal structural parameters of the piezoelectric film are identified. Finally, the direction of the design improvement for the exciting efficiency of the transducer is provided.

scholarly journals Experimental and numerical analysis of the static strength and fatigue life reliability of parabolic leaf springs in heavy commercial trucks

2020 ◽  
Vol 12 (7) ◽  
pp. 168781402094195
Author(s):  
Ufuk Taner Ceyhanli ◽  
Mehmet Bozca
Keyword(s):  
Finite Element ◽  
Fatigue Life ◽  
Numerical Analysis ◽  
Reliability Analysis ◽  
Static Loading ◽  
Static Strength ◽  
Design Stage ◽  
Leaf Spring ◽  
Leaf Springs ◽  
Parabolic Leaf Spring

The objective of this study is to perform experimental and numerical analysis of the static strength and fatigue life reliability of parabolic leaf springs in heavy commercial trucks. To achieve this objective, stress and displacements under static loading were analytically calculated. A computer-aided design model of a parabolic leaf spring was created. The stress and displacements were calculated by the finite element method. The spring was modelled and analysed using CATIA Part Design and ANSYS Workbench. The stress and displacement distributions on a three-layer parabolic leaf spring were obtained. The high-strength 51CrV4 spring steel was used as sample parabolic leaf springs material, and heat treatments and shoot peening were applied to increase the material strength. Sample parabolic leaf springs were tested to obtain stress and displacement under static loading conditions. By comparing three methods, namely, the static analytical method, static finite elements method and static experimental method, it is observed that results of three methods are close to each other and all three methods are reliable for the design stage of the leaf spring. Similarly, sample parabolic leaf springs were tested to evaluate the fatigue life under working conditions. The reliability analysis of the obtained fatigue life test value was carried out. It was shown that both analytical model and finite element analysis are reliable methods for the evaluation of static strength and fatigue life behaviour in parabolic leaf springs. In addition, it is determined by a reliability analysis based on rig test results of nine springs that the spring achieves its life cycle of 100,000 cycles with a 99% probability rate without breaking. Furthermore, the calculated fatigue life is 2.98% greater than experimentally obtained fatigue life mean and the leaf spring can be used safely and reliably during the service period in heavy trucks.

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