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

Abstract

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.

Stiffness Prediction and Analysis of Composite Leaf Springs

“…When the structure of the composite leaf spring is symmetrical, its stiffness is In summary, the stiffness can be predicted according to (1), ( 9), (15), and ( 18) to (20).…”

“…Wang et al used the FEM to predict the stiffness and bearing capacity of a composite leaf spring for a commercial vehicle and verified the results via sample testing [19]. Kessentini et al adopted the FEM to conduct the design and static analysis of a 3D-printed carbon polyether ether ketone polymer-based composite mono leaf spring [20]. However, the FEM application involves a large modeling and operation cycle, which hampers the design and optimization of composite leaf springs in the development stage.…”

Mechanical, microstructural and numerical investigations of 3D printed carbon fiber reinforced PEEK

“…[16][17][18][19] Pagliarulo et al 20 have proposed in their research works a multimodal approach based on different optical techniques to characterize the FDM-printed PEEK samples reinforced with randomly distributed carbon fibers at multi-scales. Carbon fibers are characterized by excellent functionality which leads to produce advanced materials with much higher mechanical performances as proven by Blyweert et al, Kessentini et al, and Zhang et al [21][22][23] However, the 3D printing technology is mainly depending on a large number of parameters that should be tested and reported to extend this technology for functional parts. 24,25 Hence, there is a need to understand the involved factors in order to find the best conditions for printing composite materials with improved mechanical properties.…”