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Design Optimization and FE Analysis of 3D Printed Carbon PEEK Based Mono Leaf Spring
Amir Kessentini1,2, Gulam Mohammed Sayeed Ahmed3, Jamel Madiouli4,5
1Department of Mechanical Engineering, College of Engineering, King Khalid University, P.O. Box 9004, Abha-61413, Asir, Saudi Arabia. akessentini@kku.edu.sa.
Micromachines
|May 1, 2019
Summary
This study optimized 3D printed carbon PEEK composite leaf springs using finite element analysis. Results show potential for lighter, stronger leaf springs with improved load capacity and reduced stress.
Area of Science:
- Materials Science
- Mechanical Engineering
- Automotive Engineering
Background:
- Traditional leaf springs are heavy and prone to fatigue.
- 3D printing offers novel manufacturing possibilities for automotive components.
- Carbon PEEK composites provide high strength-to-weight ratios.
Purpose of the Study:
- To design and analyze 3D printed carbon PEEK composite mono leaf springs.
- To optimize material and design parameters for enhanced performance.
- To compare performance against traditional leaf springs for a Dodge SUV.
Main Methods:
- Finite Element Analysis (FEA) for static analysis and design optimization.
- Investigated parameters: fiber diameter, length, volume fraction (30%, 50%, 60%), and orientation (0°, 45°, 90°).
- Response surface optimization methodology used for parameter selection.
Main Results:
- Evaluated effects of parameters on deflection, bending stress, spring rate, stiffness, and von Mises stress.
- Demonstrated potential for weight reduction in 3D printed leaf springs.
- Identified optimized design parameters for minimum deflection and bending stress.
Conclusions:
- 3D printed carbon PEEK composite leaf springs offer a lighter alternative with superior load-carrying capacity.
- Optimized design parameters significantly enhance leaf spring performance.
- This technology presents an efficient solution for automotive suspension systems.
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