The advantage of leaf spring over helical spring is that the ends of the spring may be guided along a
definite path as it deflects to act as a structural member in addition to energy absorbing device. Thus
the leaf springs may carry lateral loads, brake torque, driving torque etc., in addition to shocks.
Materials: spring steel (EN45,SUP9,EN47),Plain carbon steel (0.9 to 1 % carbon), chrome vanadium steel,
alloy steel.
Mono leaf spring
Mono leaf spring (a single leaf that acts as both the master leaf as well as the spring) . Mono-leaf
springs consist of one plate of spring steel that is thick in the center and tapers out to the ends.
Multi leaf spring
It is built up of a number of plates (known as leaves). The leaves are usually given an initial curvature or
cambered so that they will tend to straighten under the load.
The longest leaf known as main leaf or master leaf has its ends formed in the shape of an eye through
which the bolts are passed to secure the spring to its supports. Usually the eyes, through which the
spring is attached to the hanger or shackle, are provided with bushings of some antifriction material
such as bronze or rubber. The other leaves of the spring are known as graduated leaves.
The leaves are held together by means of a band shrunk around them at the centre or by a bolt passing
through the centre. Since the band exerts a stiffening and strengthening effect, therefore the effective
length of the spring for bending will be overall length of the spring minus width of band.
In case of a centre bolt, two-third distance between centres of U-bolt should be subtracted from the
overall length of the spring in order to find effective length.
The spring is clamped to the axle housing by means of U-bolts.
t = Thickness of plate,
b = Width of plate, and
L = Length of plate or distance of the load W from the cantilever end.
We have already discussed that the effective length of the spring,
2L = 2L1 – l ...(When band is used)
= 2L1 - 2/3*l ... (When U-bolts are used)
It may be noted that when there is only one full length leaf (i.e. master leaf only), then the number of
leaves to be cut will be n and when there are two full length leaves (including one master leaf), then the
number of leaves to be cut will be (n – 1). If a leaf spring has two full length leaves, then the length of
leaves is obtained as follows :
Equalised Stress in Spring Leaves (Nipping)
We have already discussed that the stress in the full length leaves is 50% greater than the stress in the
graduated leaves.
Nipping: the process of equalizing the stress in full length leaves and graduated leaves by using
different radii of curvature is called nipping. The pre-stressing is achieved by bending the leaves
to different radii of curvature, before they are assembled with the centre clip. As shown in Fig,
the full-length leaf is given a greater radius of curvature than the adjacent leaf. The radius of
curvature decreases with shorter leaves.
Nip: The initial gap C between the extra full-length leaf and the graduated-length leaf before the
assembly is called a ‘nip’.
Nipping is common in automobile suspension springs. When the central bolt, holding the various
leaves together, is tightened, the full length leaf will bend back as shown dotted in Fig. 23.31 and
have an initial stress in a direction opposite to that of the normal load. The graduated leaves will
have an initial stress in the same direction as that of the normal load. When the load is gradually
applied to the spring, the full length leaf is first relieved of this initial stress and then stressed in
opposite direction
FOS=2 to 2.5 for automobile suspension
D-12: Design a semi-elliptical laminated spring for the rear wheel of a truck. Rear wheels have to carry
a load of 15 kN. The span of spring is to be taken 1.1 m and there may be 10 number of leaves.
Solution. Given : Total load = 15 kN ; No. of springs = 2; z = 10 ; 2L1 = 1100 mm, L2 = 200mm(assume), L =
(2L1-L2)/2 = 450 mm ; assume E = 200 kN/mm2 = 200 × 103 N/mm2; σ = 400 MPa = 400 N/mm2
(1) b and t dimensions of spring
We know that load on each spring,
2W =Total load 15/2=7.5 kN
W = 17.5 / 2 = 3750 N
Let t = Thickness of the leaves, and b = Width of the leaves= 5t. We know that bending stress (σ),
WL
𝜎= = 400
zbt2
t= 7.9 mm say 8 mm, b= 40 mm
(2) length of leaves
Length of the smallest leaf = Effective length/( n-1) + Ineffective length
=300 mm
2nd leaf length =400, 500, 600, 700, 800,900,1000,1100 mm
We know that length of the master leaf =2 L1 + π(d + t) 2
First find the eye diameter by using bearing strength
We know that the load on pin
W = d*b*pb (pb =10MPa, b =40mm)
d= 9.3 say 18 mm (table-14.12)
Maximum bending moment on the pin,
M = W*l3/4 =37500 Nmm
l3= b+4 mm= 44 mm
section modulus, Z = π *d3/32= 0.0982 d3
We know that bending stress (assume =100 MPa) (σb),
100 =M/Z
d= 15.6 say 18 mm
let us now check the pin for induced shear stress. Since the pin is in double shear , therefore load on the
pin
W= 2*π*d2*τ/4
τ= 7.3 MPa , so design is safe
Mater leaf length = 1100+2*3.14*26= 1263.3 mm
D-13: Design a semi-elliptical laminated spring for the rear wheel of a truck. Rear wheels have to carry
a load of 10 kN. The span of spring is to be taken 1 m and there may be 10 number of leaves.
Solution. Given : Total load = 10 kN ; No. of springs = 2; z = 10 ; 2L1 = 1000 mm, L2 = 100mm(assume), L =
450 mm ; assume σ = 400 MPa = 400 N/mm2
(1) b and t dimensions of spring
We know that load on each spring,
2W =Total load 10/2=5 kN
W = 5 / 2 = 2500 N
Let t = Thickness of the leaves, and b = Width of the leaves= 5t. We know that bending stress (σ),
WL
𝜎= = 400
zbt2
t= 6.9 mm say 7 mm, b= 5t= 35 mm say 40 mm (table 14.9)
(2) length of leaves
Length of the smallest leaf = Effective length/( n-1) + Ineffective length
=200 mm
2nd leaf length = 300, 400, 500, 600, 700, 800,900,1000 mm
We know that length of the master leaf =2 L1 + π(d + t)*2
First find the eye diameter by using bearing strength
We know that the load on pin
W = d*b*pb (pb =10MPa, b =40mm)
d= 6.25 say 18 mm (table-14.12)
Maximum bending moment on the pin,
M = W*l3/4 =25000 Nmm
l3= b+4 mm= 44 mm
section modulus, Z = π *d3/32= 0.0982 d3
We know that bending stress (assume =100 MPa) (σb),
100 =M/Z
d= 13.6 say 18 mm
let us now check the pin for induced shear stress. Since the pin is in double shear , therefore load on the
pin
W= 2*π*d2*τ/4
τ= 4.9 MPa , so design is safe
Mater leaf length = 1000+2*3.14*25= 1157 mm
D-15: design a leaf spring for the following data. Total load = 150 kN, number of springs =4, maximum
number of leaves =10, span of spring = 1m, permissible deflection = 85 mm, E= 200kN/mm 2, allowable
stress in spring = 600 MPa.
Solution. Given : Total load = 150 kN ; No. of springs = 4; z = 10 ; 2L 1 = 1000 mm or L = 450 mm ; y = 85
mm ; E = 200 kN/mm2 = 200 × 103 N/mm2; σ = 600 MPa = 600 N/mm2
(2) b and t dimensions of spring
We know that load on each spring,
2W =Total load 150/4=37.5 kN
W = 37.5 / 2 = 18750 N
Let t = Thickness of the leaves, and b = Width of the leaves= 5t. We know that bending stress (σ),
WL
𝜎= = 600
zbt2
t= 11.9 mm say 12 mm
12WL3
𝛿= = 85
Ebt3(2ig+3if)
t= 10.23 say 12 mm, b= 5t= 60mm
(2) length of leaves
Length of the smallest leaf = Effective length/( n-1) + Ineffective length
=200,
2nd leaf length = 300, 400, 500, 600, 700, 800,900,1000 mm
We know that length of the master leaf =2 L1 + π(d + t) 2
First find the eye diameter by using bearing strength
We know that the load on pin
W = d*b*pb (pb =10MPa, b =60mm)
d= 31.2 say 32 mm
Maximum bending moment on the pin,
M = W*l3/4 =300000 Nmm
l3= b+4 mm= 64 mm
section modulus, Z = π *d3/32= 0.0982 d3
We know that bending stress (assume =100 MPa) (σb),
100 =M/Z
d= 31.2 say 32 mm
let us now check the pin for induced shear stress. Since the pin is in double shear , therefore load on the
pin
W= 2*π*d2*τ/4
τ= 11.6 MPa , so design is safe
Mater leaf length = 1000+2*3.14*44= 1276.3 mm
D-14,D-17: a semi-elliptical laminated spring is to carry a load of 5000 N and consists 8 leaves 46 mm
wide , two of leaves being of full length. The spring is to be made 1000 mm between the eyes and is
held at the centre by a 60 mm wide band. Assume that the spring is initially stressed so as to induce
an equal stress of 500 N/mm2 when fully loaded. Design the spring giving (a) thickness of leaves (b)
eye diameter (c) length of leaves (d) maximum deflection and camber. Assume E= 200kN/mm 2
Solution. Given : Total load = 5000 N ; No. of springs = 1; z = 8 ; 2L 1 = 1000 mm, L2 = 60 mm, L = 470 mm ;
b= 46mm, E = 200 kN/mm2 = 200 × 103 N/mm2; σ = 500 MPa = 500 N/mm2
(1) b and t dimensions of spring
We know that load on each spring,
2W =Total load 5000 N
W = 5000 / 2 = 2500 N
Let t = Thickness of the leaves, and b = Width of the leaves= 46mm. We know that bending stress (σ),
WL
𝜎= = 500
zbt2
t= 6.2 mm say 6.5 mm
(2) length of leaves
Length of the smallest leaf = Effective length/( n-1) + Ineffective length
=940/7 + 60 = 194 mm
2nd leaf length =328 mm, 462, 596, 730, 864,1000 mm
We know that length of the master leaf =2 L1 + π(d + t)*2
First find the eye diameter by using bearing strength
We know that the load on pin
W = d*b*pb (pb =10MPa, b =46 mm)
d= 5.43 mm say 18 mm
Maximum bending moment on the pin,
M = W*l3/4 =31250 Nmm
l3= b+4 mm= 50 mm
section modulus, Z = π *d3/32= 0.0982 d3
We know that bending stress (assume =100 MPa) (σb),
100 =M/Z
d= 14.7 say 18 mm
let us now check the pin for induced shear stress. Since the pin is in double shear , therefore load on the
pin
W= 2*π*d2*τ/4
τ= 4.9 MPa , so design is safe
Master leaf length = 1000+2*3.13*24.5 = 1153.8 mm
(3) maximum deflection
WL3
𝛿= = 68.4 mm
Ebt3(2ig+3if)
(4) eye diameter
d= 18mm
(5) camber
camber = 68.4 mm
(6) Radius to which the leaves should be initially bent
y (2R – y)=( L1)2
R=1861.6 mm
Dec-2017, Dec-2015. Design a leaf spring for the following specifications : Total load = 140 kN ; Number
of springs supporting the load = 4 ; Maximum number of leaves = 10; Span of the spring = 1000 mm ;
Permissible deflection = 80 mm. Take Young’s modulus, E = 200 kN/mm2 and allowable stress in spring
material as 600 MPa.
Solution. Given : Total load = 140 kN ; No. of springs = 4; n = 10 ; 2L = 1000 mm or L = 500 mm ; δ = 80
mm ; E = 200 kN/mm2 = 200 × 103 N/mm2; σ = 600 MPa = 600 N/mm2
We know that load on each spring,
(1) b and t dimension of spring
2W =Total load 140/4=35 kN
W = 35 / 2 = 17.5 kN = 17500 N
Let t = Thickness of the leaves, and b = Width of the leaves= 5t. We know that bending stress (σ),
WL
𝜎= = 600
zbt2
Zbt2= 87.5 × 103
t= 12.05 mm
12WL3
𝛿= = 200
Ebt3(2ig+3if)
t= 13.14 say 14 mm, b= 70mm
(2) length of leaves
Length of the smallest leaf = Effective length/( n-1) + Ineffective length
=110 mm
2nd leaf length =220 mm, 330, 440, 550, 660, 770, 880,1000 mm
We know that length of the master leaf =2 L1 + π(d + t) 2
Maximum bending moment on the pin,
M = W*l2/4 =323750 mm
l2= b+4 mm= 74 mm
section modulus, Z = π *d3/32= 0.0982 d3
We know that bending stress (assume =80 MPa) (σb),
80 =M/Z
d= 34.5 say 35 mm
Mater leaf length = 1000+2*3.14*49= 1308 mm
(3) Radius to which the leaves should be initially bent
y (2R – y)=( L1)2
R=775 mm
EN45, EN47,SUP9- Spring steel
