BHARATI VIDYAPEETH COLLEGE OF ENGNEERING

A-Y-2025-2026
MINI PROJECT ON
DESIGN ANALYSIS AND OPTIMIZATION OF VEHICLE
COMPONENT
BE(MECHANICAL) SEM – 7 GROUP NO - 22
NAME MIS NO ROLL NO

SACHIN NARENDRA GOSAVI 23162020 4816

SHUBHAM JITENDRA MAURYA 23162027 4819

PANKAJ RAMIQBAL SHARMA 23162059 4846

SARVESH AVINASH ZUNJARRAO 23162021 4856

GUIDE - Dr. GANESH S. KADAM

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Content
•INTRODUCTION •POSSIBLE UPGRADTION FOR LEAF SPRING
IN ANSYS
•LITREATURE SURVEY
•ADDRESSING CHALLENGES IN LEAF
•ANSYS
SPRING DEVELOPMENT
•ABOUT LEAF SPRING
•CONCLUSION
•WHAT IS LEAF SPRING
•REFERENCES
•FEA OF LEAF SPRING USING ANSYS

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Introduction
•Design and analysis of vehicle components play a critical role in ensuring the performance, safety, comfort,
and efficiency of modern automobiles.

• Each component—whether structural, mechanical, or dynamic—must meet strict standards of durability,

• Engineers use computer tools to analyze the parts to see how they perform under different loads and
situations.

•This helps improve the quality, reduce weight, and lower fuel consumption. Overall, the design and analysis
of vehicle components are key steps in building reliable and high-performing vehicles.

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Literature Survey
AUTHOR COMPONENT YEAR SUMMARY
The study focuses on the structural design and stress analysis of a ladder chassis using
[Link] CHASSIS 2021
ANSYS.
Studied thermal and structural behavior of disc brakes using FEA. Gray cast iron and
Kiran et al. BRAKE SYSTEM (DISC) 2022
carbon composites were compared for thermal stress.
2019 Analyzed the part that connects wheels and suspension. Found weak areas and
Steering Knuckle Steering Knuckle
redesigned it for better safety
Designed a lighter chassis using aluminum instead of steel. It made the vehicle lighter
Balasubramani et al. Chassis (Aluminum) 2019
and more fuel efficient.
Analyzed the part that connects wheels and suspension. Found weak areas and
Rajesh Kotha et al Wheel Rim 2021
redesigned it for better safety
Designed and analyzed a multi-leaf spring using ANSYS. Found stress concentration at
Pendyala et al. Leaf spring 2019
the center bolt area.
Analyzed a parabolic (tapered) leaf spring. It performed better than a traditional multi-
Thakur et al. Parabolic Leaf Spring 2023
leaf spring due to even stress distribution and lower weight.
Developed improved simulation methods that capture stress at leaf interfaces (not just
Balasubramani et al. LEAF SPRING 2024
center).
Parabolic vs. Conventional Leaf FEA comparison using ANSYS showed parabolic springs reduce weight and improve
Rajesh Kotha et al 2024
Springs ride comfort compared to multi-leaf steel springs.
Modeled carbon-fiber parabolic leaf springs and tested under cyclic loads. Found that
Fatigue Behavior of Parabolic Leaf
Pendyala et al. 2024 parabolic shape with reduced thickness profile improves fatigue life and load
Springs
distribution.

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 Ansys
•ANSYS is powerful engineering simulation software used to perform Finite Element Analysis (FEA).

• It helps engineers simulate and study how a component will respond to stress, heat, vibration, and other
forces before actually manufacturing it.

•Vehicles are made up of many critical components such as the chassis, suspension, brakes, steering system, and
transmission. These parts must be properly designed to ensure the vehicle is safe, durable, and efficient.

•For example, ANSYS can show if a vehicle part will bend, crack, or fail under certain loads. This allows
engineers to fix problems early in the design phase, reduce weight by removing unnecessary material, and
improve performance and safety.

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About Leaf Spring
The leaf spring is an important suspension component used in vehicles to absorb shocks and provide
stability. In this project, we focus on the design, modeling, and analysis of a leaf spring using FEA tools.
The aim is to study stress distribution, deflection, and load-carrying capacity under different conditions. We
also explore material selection and optimization techniques to improve performance and reduce weight.
This helps in enhancing ride comfort, safety, and durability of the vehicle suspension system.

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What Is Leaf Spring
•A leaf spring is a simple form of spring commonly used in vehicle suspension systems to absorb shocks and
support the weight of the vehicle..

•The leaf spring connects the axle to the vehicle’s chassis, allowing controlled movement and reducing
vibrations caused by uneven road surfaces.

•It is widely used in trucks, vans, and trailers due to its durability, load-bearing capacity, and cost-
effectiveness.

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FEA Of Leaf Spring Using Ansys
•Geometry Modeling

•Material Properties

•Meshing

•Boundary Conditions

•Solution

•Result

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 Types Of Leaf Spring
•Semi-Elliptical – Most common (trucks, buses)

•Quarter Elliptical – Vintage cars, trailers

•Full Elliptical – Antique vehicles

•Transverse – Early Fords, sports cars

•Parabolic – Modern LCVs, smoother ride

•Composite Leaf Spring – Lightweight, corrosion-resistant

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 Possible Upgradation For Leaf Spring In Ansys
Geometric modelling :

•Thickness: Vary the thickness along the length of the leaf to reduce stress concentrations.

•Width: Use a variable width design wider in the center and narrower at the ends.

•Length: Adjust eye-to-eye length depending on vehicle requirements.

Why Modify ?

•To reduce weight without compromising strength.

•To make the leaf spring more durable and efficient.

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 Possible Upgradation For Leaf Spring In Ansys
Fillet or rounded ends in leaf spring :

What is a Fillet ?

•A fillet is a smooth, rounded transition between two surfaces, typically used at sharp corners.

Benefits in Leaf Spring :

•Reduces stress concentration at the ends. Increases fatigue life by avoiding sharp edges where cracks can
initiate.

•Improves load transfer between leaves in a multi-leaf setup.

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Possible Upgradation For Leaf Spring In Ansys
Optimization using design xplorer :

What is Design Xplorer ?

•ANSYS Workbench auto-optimizes design parameters via simulations automatically.

How it works :

•Define input parameter

•Run simulation

•Set Output Goals

•view result

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Addressing Challenges In Leaf Spring
Development
•Noise and vibration control : improving ride comfort .

•Material optimization: balancing strength, weight , and cost.

•Corrosion protection: using coating and treatment for durability .

•Design complexity : adopting simulating tool(CAD , FEA).

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Solid Works Design

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16
Meshing of Designed Model

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Ansys Results For Aforementioned Materials
Steel :

Fig.8 Maximum Principal Stress

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Fig.9 Maximum Principal Elastic Strain

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Fig.10 Total Deformation

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Fig.11 Directional Deformation (X-axis)

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Fig.12 Equivalent Von-Mises Stress

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 Parameter
S. No. Maximum Minimum

1 Maximum Principal Stress

2 Maximum Principal Strain 0.002945 3.88e-9

3
Total Deformation (m) 0.00716 0

4
Directional Deformation (m) 0.00152 -0.00152

5
Equivalent Stress (MPa) 948.45 0.0012741

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E-Glass/Epoxy :

Fig.13 Maximum Principal Stress

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Fig.14 Maximum Principal Elastic Strain

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Fig.15 Total Deformation

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Fig.16 Directional Deformation (X-axis)

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Fig.17 Equivalent Von-Mises Stress

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 Parameter
S. No. Maximum Minimum

1
Maximum Principal Stress (MPa) 522.12 -66.6

2 Maximum Principal Strain 0.00058943 4.135e-10

3
Total Deformation (m) 0.0013688 0

4
Directional Deformation (m) 0.0003127 -0.00031275

5
Equivalent Stress (MPa) 822.67 0.0007986

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Fig.18 Graph- Stress v/s Load

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Results
Conventional Steel E-Glass/Epoxy
Parameter Leaf Spring composite leaf spring

Maximum Principal Stress (MPa) 618.2 522.12

Maximum Principal Strain 0.002945 0.00058943

Total Deformation (m) 0.00716 0.0013688

Directional Deformation (m) 0.00152 0.0003127

Equivalent Stress (MPa) 948.45 822.67

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Fig.19 Graph displaying reduction (in Orange) percentage with Epoxy

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Discussion
• Epoxy leaf spring deflection for a particular load is less compared to conventional steel leaf spring.

• Maximum stresses produced in epoxy leaf spring is lower as compared to steel leaf spring.

• Directional Deformation in epoxy spring is low as compared to steel leaf spring.

• Weight reduction due to lighter weight of epoxy springs for same stresses as compared to steel leaf
spring i.e., 74.55% reduction in weight.

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 Conclusion
•The project successfully demonstrated the design, analysis, and optimization of a leaf spring using ANSYS
Workbench.

•Through geometric modifications and material upgrades, significant improvements in performance and
weight reduction were achieved.

•FEA results helped identify high-stress regions and deformation zones, enabling targeted design
enhancements.

•Filleting and rounded ends reduced stress concentrations and increased fatigue life.

•Using Design Xplorer, optimal combinations of thickness, width, and material were identified for better
durability and efficiency.

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References
[1]R.S. Khurmi & J.K. Gupta, Machine Design, S. Chand Publications

[2]ANSYS Documentation, ANSYS Workbench User Guide and Tutorials

[3]J. Vijayarangan and V. Rajendran, Design and Analysis of a Composite Leaf Spring, Journal of Institute of
Engineers

[4]B.V. Rao and P. K. Sharma, Optimization of Leaf Spring Using Finite Element Method, International
Journal of Engineering Research

[5]Automobile Engineering by Kripal Singh8. Tutorials Point & YouTube Channels (e.g., LearnCAx,
SimuTech Group) for ANSYS Workbench learning

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[6]Nutalapati, “Design and analysis of Leaf Spring by using Composite material for light vehicles”, IJMET
Volume 6, Issue 12, pp. 36-59, Dec 2015
[7]Kumar & Reddy, “Modelling and structural analysis of Leaf Spring using Finite Element Method”,
[8] IRJET, Volume: 04 Issue: 12, Dec-2017
[9]Ashwini & Rao, “Design and Analysis of Leaf Spring using Various Composites- An Overview”,
[10] Materials Today: Proceedings 5, 5716–5721, 2018
[11]Dwivedi & Jain, “Design and Analysis of Automobile Leaf Spring using ANSYS”, TROI, pp 28-35, 2016
[12]Pankaj Saini et. al., “Design and Analysis of Composite Leaf Springs for light vehicles”, IJIRC, Vol. 2,
[13]Issue 5, May 2013
[14]Ramakant & Sowjanya, “Design and analysis of automotive multi leaf springs using composite material”,
IJMPERD 2249-6890, Vol. 3, Issue 1, pp. 155-162, March 2013
[15]Kothari et. al., “Comparison of Performance of Two Leaf Spring Steels Used for Light Passenger
Vehicle”, VSRD-MAP 2249-8303, Volume-2, pp. 9-16, 2012

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[16] V. Lakshmi Narayana, “Design and Analysis of Mono Composite Leaf Spring for Suspension in
Automobiles”, IJERT 2278-0181, Vol. 1 Issue 6, August- 2012
[17] Shokrieh & Rezaei, “Analysis and optimization of a composite leaf spring”, Composite Structures, pp. 317–325,
2013
[18] S. Venkatesh et. al., IRACST – Engineering Science and Technology: An International Journal (ESTIJ),ISSN:
2250-3498, Vol.2, No. 4, August 2012
[19] Goud & Harinath, “Static Analysis of Leaf Spring”, International Journal of Engineering Science and
Technology (IJEST), ISSN: 0975-5462, Vol. 4 No. 08, August 2012.
[20] Arun & Chithambaranathan, “Static Analysis of Hybrid Composite Leaf Spring “, International Journal of
Engineering Sciences & Research Technology, Vol. 3, pp. 77-80, June- 2014

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Thank You

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