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Module7
Design of Springs
Version 2 ME , IIT Kharagpur
Lesson3
Design of Leaf Springs
Version 2 ME , IIT Kharagpur
Instructional Objectives:
At the end of this lesson, the students should be able to understand:
•Working of leaf spring
•Types of leaf springs
•Design theme of leaf springs
•Laminated spring and its modifications
7.3.1 Leaf Springs
In order to have an idea of working principle of a leaf spring, let us
think of the diving board in a swimming pool. The diving board is a
cantilever with a load, the diver, at its free end. The diver initiates
a to and fro swing of the board at the free end and utilizes the spring
action of the board for jumping. The diving board basically is a leaf
spring.
The leaf springs are widely used in suspension system of railway
carriages and
automobiles. But the form in which it is normally seen is laminated leaf
spring.
A simple cantilever type leaf spring is shown in the Fig. 7.3.1.
L
b
b
F
h
uniform
strength
(1)
(2)Fig.7.3.1
In the cantilever beam type leaf spring, for the same leaf thickness, h,
leaf of uniform width, b (case 1) and, leaf of width, which is uniformly
reducing from b (case 2) is considered. From the basic equations of
bending stress and deflection, the maximum stress,
and tip deflection,
can be derived.
max
σ
max
δ

For ca e 1(uniform wi th)
(7.3.1)
max
2
3
max
3
6FL
bh
4FL
Ebh
σ
=
δ
=

Where,E i the Ela tic mo ulu of the pring material.
Ver ion 2 ME , IIT Kharagpur


For ca e 2(non uniform wi th)
(7.3.2)
max
2
3
max
3
6FL
bh
6FL
σ
=
Ebh
δ
=





In the econ ca e it
i ob erve that in tea of uniform wi th leaf,
ifa
leaf of varying

wi th (triangular one a hown in the

figure) i
u e , the ben ing tre at any cro ection i ame an equal to
max

σ. Thi i calle a leaf of a uniform


trength. Moreover, the tip eflection
being more, comparatively, it ha
greater re ilience than it uniform wi th counterpart.

Re

ilience, a we
know, i the capacity

to ab orb potential energy uring eformation.
However, one houl keep
b
uniform
trength
Fig. 7.3.2




in min
that in or er to with tan
the hear force the tip ha to have
ome wi th.

Thi i hown a a
re zone in the figure.
In one way non
uniform wi th leaf i a better e ign than a uniform wi th leaf.


Leaf pring of imply upporte beam type i hown in the Fig. 7.3.3,
for which


the tre an eflection equation are al o given a in the ca e of
cantilever.

For ca e 1(uniform wi th)
(7.3.3)

For ca e 2(non uniform wi thLozenge- hape)
L
b
F
h
uniform
trength
(1)
b
(2)
upport
reaction
Fig. 7.3.3
max
2
3
max
3
3FL
bh
2FL
Ebh
σ
=
δ
=
(7.3.4)
max
2
3
max
3
3FL
bh
σ
=
3FL
Ebh
δ
=


One of the application of leaf pring of imply upporte beam type i

een in automobile , where, the central location of the pring i fixe
to the

wheel axle. Therefore, the wheel exert the force

F (oppo ite to
the irection
hown in the figure), on the pring an upport reaction
at the two en of the pring come
Ver ion 2 ME , IIT Kharagpur





from the carriage.

The iamon hape leaf, hown a ca e 2, i name a
Lozenge hape an it i again a beam of uniform trength.
7.3.2De ign theme of a leaf pring



Let u con i er the
imply
upporte leaf of Lozenge hape for which

the
maximum

tre an maximum eflection are known. From the tre an
eflection

equation the thickne of the pring plate, h, can be
obtaine a ,
(7.3.5)
2
 2

max
e

max
e
L
L
hE
E
σ
σ
=
=
δ
δ





Theσmax

i replace by e ign tre
σ
e . Similarly,δmax

i replace
byδ e .E i the material property an epen on the type of pring
material
cho en.L i the characteri tic length of
the pring. Therefore,
once the e ign parameter

, given on the left i e of the above

equation, are fixe the value of plate thickne ,h can be calculate .


Sub titution

ofh in the tre equation above will yiel the value of
plate wi thb.
(7.3.6)

2
e
3FL
b
h
=
σ



In the imilar

mannerh
an b can be calculate for leaf pring of ifferent
upport con ition

an beam type .
7.3.3 Laminate Spring


One of the ifficultie
of the uniform trength beam, ay Lozenge
hape,
i that the value of wi thb ometime i too
large to accommo ate in a
machine

a embly. One practice i that
in tea of keeping thi large
wi th one can make everal lice an put
the piece together a a
laminate. Thi i the concept of laminate
pring. The Fig.7.3.4 how
the concept of formation of a laminate pring.
Ver ion 2 ME , IIT Kharagpur
2
442
133

Laminate Spring
Fig. 7.3.4



The

Lozenge

hape plate i cut into everal longitu
inal trip , a
in icate in the
figure. The central trip, marke
1 i the ma ter leaf
which

i place

at the top. Then two
piece
, marke 2 are put together,
i e by i e to form another leaf an place
below
the top leaf. In the
imilar

manner
other pair of

trip , marke 3 an 4 re pectively
are
place in the
ecrea ing or er of trip length to form a laminate
pring. Here wi th of each trip,
i given a ,
N
 b
,
WhereN i the number of trip
(7.3.7)
N
b
b=N

In
practice, trip of wi th,
an length , ay equal to trip1,
trip2 etc., a



hown in the example, are cut an put

in the laminate form. The tre an
eflection equation for a laminate pring i ,
N
b
(7.3.8)
3
max
max
2
3
N
N
pFL
qFL


an
Nb h
ENb h
σ
=
δ
=

Where,con tant p an q are given a ,
p
q

Simply upporte beam:3
3
Cantilever beam
:6
6





It i to be note that the en of the
leave are not harp
an pointe ,
a hown in figure.
In fact they are ma e blunt or even
ma e traight to

increa e the loa bearing capacity. Thi change from i eal ituation
oe not have much
effect on the tre equation. However, mall effect
i there on the eflection equation.



In the following ection we will i cu about few more con tructional
etail
of a
laminate leaf pring.
Ver ion 2 ME
, IIT Kharagpur
7.3.4Laminate emi-elliptic pring
pan 2L
camber
ma ter
leaf
reboun clip
central


clamp
gra uate leave
eye

Laminate emi-elliptic pring
Fig 7.3.5


The Fig 7.3.5 how a laminate emi- elliptic

pring. The top leaf i
known a the ma ter leaf. The eye i provi e
for attaching the pring
with another machine member. The amount of ben that i given to the
pring from the central line,

pa ing through the eye , i known
a
camber.


The camber i
provi e o that even at the maximum loa the
eflecte

pring houl not touch the machine member to which it i
attache . The camber hown in
the figure

i known a po itive camber.
The central clamp i require

to hol the leave of the pring. However,
the bolt hole require to engage
the bolt to clamp the leave
weaken
the pring to ome extent.

Reboun clip help to hare the loa from the
ma ter leaf to the gra uate leaf.
7.3.5Material for leaf pring

Material for leaf pring are not a goo a that for the helical pring.


Plain
carbon teel, Chromium vana ium teel, Chromium- Nickel-
Molyb enum
teel, Silicon-

mangane e teel, are the typical material
that are u e in the e ign of leaf pring .



7.3.6Stan

ar ize of leaf pring
Wi th (mm)
: 25-80 mm in tep of 5mm
Thickne (mm)
: 2-8 mm in tep of 1mm, 10-16 mm in tep of 2mm
Ver ion 2 ME , IIT Kharagpur





In or
er to carry heavy loa few more a itional

full length leave are
place


below the ma

ter leaf for heavy loa . Such alteration

from the
tan ar laminate leaf pring,
what we have learnt above, oe not
change the tre value, but eflection equation require ome correction.
3
c
max
3
N
qFL
ENb h
δ
δ
=
(7.3.9)

Where, correction in eflection,δc i given a ,
where,
Number of full length leave
Total number of leave in the pring
2
c
3
f
f
1.0 4m 2m{1.5 ln(m)}
(1.0 m)
N
mN
NN−
+
−
δ=
−
==
=

7.3.7Stresses ue to support hinges



The master leaf of
a laminate spring
is hinge
to the supports.
The
support
forces in uce, stresses ue to longitu inal forces an stresses

arising
ue to possible twist.Hence,


the master
leaf
is more

stresse
compare to other

the gra uate leaves. Metho s to re uce a itional
stresses coul be,


1.Master leaf is ma
e of stronger material than the other leaves.

2.Master

leaf is ma
e thinner than the other leaves. This will re uce the
ben ing stressas evi ent from stress equation.

3.Another common practice is to increase the ra ius of curvature of the
master
leaf than the
next leaf.

The last metho is
explaine through Fig 7.3.6.
Initial bent
create through
fixing bolt

uring assembly
Larger ra ius
of curvature
U
Nipping of leaf spring
Version 2 ME , IIT Kharagpur
Fig 7.3.6



The


master leaf has a larger
ra ius of curvature compare to the

a itional leaf that is place
below
so obviously a gap will be create
between the


two leaves as in icate in the figure. Now, an initial bent
is create uring assembly by tightening the
central
bolt. Therefore,


some amount of compressive stress will be pro uce at
the insi e
curvature of the master leaf. Similarly,
at
the outsi e curvature of the
master leaf tensile stress will be pro uce . Both these stresses are
initial stresses in the master leaf.

However, by such operation
of
tightening the central bolt,
the a itional leaf
that is place beneath
the master leaf

has a ten ency to flatten out an as a result the stress
pattern of the a itional leaf

will be reverse of that of
the master
leaf, tensile
stress
is pro uce at the inner curvature an compressive
stress


is pro uce at the outer curvature.



Hence, when the spring is
loa e , for
both
the master leaf an the a
itional leaf, tensile stress
will

be
pro uce at the inner curvature an
compressive stress will be
pro uce at the outer
curvature.

Therefore, ue to opposite nature of
initial stress an loa ing stress, the master
leaf will experience
lesser stress on
both
the surfaces. However,

ue to same nature of

initial
stress an loa ing stress, the a itional
leaf is stresse more
compare to the

master leaf. But, it is to be note
that the higher
stress on the a itional leaf is actually share between all other
leaves than the master leaf. This practice of stress relief in the
master leaf is known asNipping
of leaf
spring. As a matter of fact, all
the leaves of a laminate leaf spring o have certain amount of nipping,
so that there will
be gaps between

the leaves,

as a result the stresses

will be uniformly istribute an accumulate usts can also be cleane .
Sample problem




Design a leaf spring to
carry a loa of 3400N
an place over a
span of
800 mm. The spring can eflect by 50mm. Consi
er, allowable ben ing
stress for the spring material as 350 MPa an E=2 (10)5 MPa.




Let us consi er the esign to be base on uniform strength beam. Then from


section 7.3.2 we fin that,
2
2
5
350 400
56
6

2 1050

es
es
L
Leaf thickness,h
.mm
mm
E
σ
δ
×
=
=
=
≈
×
×
2
2
3
3 3400 400324

350 50
e
FL

Leaf wi th,b
mm
h
σ
×
×
=
=
≈
×



It i ob erve that the wi th i too large to accommo ate a a machine
member.


Hence, if we con i er, ay 6 pring , then wi th of each pring become
54mm.
Ver ion 2 ME
, IIT Kharagpur
Que tion an an wer
Q1. What are the form of leaf pring ?


A1. Leaf
pring are of two form : cantilever an imply upporte type.
Q2. What oe the term “uniform trength” in the context of leaf pring
mean?


A2. If the leaf pring ha
a hape of uniformly varying wi th ( ay
Lozenge hape) then the
ben ing tre at all ection remain uniform.
The ituation i al
o i entical a before in ca e of varying thickne ,
the thickne houl vary non-uniformly with length to make a beam of
uniform trength (L/h2 = con tant). The
e leave require
le er
material, have more re ilience

compare to a con tant wi th leaf. The e
type of pring are calle leaf pring of uniform trength.


Q3. What i “nipping” in a laminate pring?



A3. In general the ifferential


curvature
between the ma ter
leaf an
the next leave i provi e in a laminate pring, where, ra iu
of
curvature being more for the ma ter
leaf. Thi con truction re uce the
tre in the
ma ter leaf a compare to the other leave of the pring

in a laminate pring. Thi type of con tructional feature i terme
a nipping.
Reference


1.V.Maleev an
Jame

B. Hartman , Machine De ign, CBS Publi her An
Di tributor .3r
E ition. 1983.
2.J.E Shigley an C.R
Mi chke , Mechanical Engineering De ign , McGraw
Hill Publication, 5thE ition. 1989.


3.M.F

Spott , De ign of Machine Element , Prentice Hall In ia Pvt. Limite ,
6thE ition, 1991.
Ver ion 2 ME , IIT Kharagpur

21 De ign of Leaf Spring

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