Title: Function integration concept design applied on CFRP cross leaf spring suspension

Authors: Andrea Airale; Alessandro Ferraris; Shuang Xu; Lorenzo Sisca; Paolo Massai

Addresses: DIMEAS – Politecnico di Torino corso, Duca degli Abruzzi 24, Torino, 10129, Italy ' DIMEAS – Politecnico di Torino corso, Duca degli Abruzzi 24, Torino, 10129, Italy ' DIMEAS – Politecnico di Torino corso, Duca degli Abruzzi 24, Torino, 10129, Italy ' DIMEAS – Politecnico di Torino corso, Duca degli Abruzzi 24, Torino, 10129, Italy ' DIMEAS – Politecnico di Torino corso, Duca degli Abruzzi 24, Torino, 10129, Italy

Abstract: In automotive systems, lightweight design is nowadays a mandatory target. Suspension systems, which are a safety system and contribute to overall vehicle performance (dynamic, comfort, noise and vibration, etc…), are one of the most complex systems in which to achieve lightweight targets. This paper discusses the development of a CFRP Cross Leaf Spring Prototype (TRL 6). The entire workflow, starting from kinematic design, multibody vehicle dynamics analysis, finite element method (FEM) structural analysis, prototype construction, testing and correlations is shown. Also studied in this project is the integration and applications of advanced continuous fibre reinforced thermoplastic polymer (CFRTP). This system, in comparison to traditional solutions, could guarantee: around 75% weight savings, suspension component optimisation, an optimisation of the suspension volume (resulting in more space for vehicle occupants), easy integration of advanced process using CFRTP, and a sustainable cost solution.

Keywords: cross leaf spring suspension; thermoplastic composite; CFRP; continuous fibre reinforced thermoplastic polymer; innovative suspensions; FEM analysis; engineering methodology.

DOI: 10.1504/IJAUTOC.2017.091421

International Journal of Automotive Composites, 2017 Vol.3 No.2/3/4, pp.276 - 293

Received: 24 Feb 2017
Accepted: 10 Oct 2017
Published online: 30 Apr 2018 *

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