Composite Suspension Leaf Springs: The Smart Solution

William Pinch; Peter Kuhn

doi:10.4271/2020-01-0991

The paper addresses three primary areas relative to Composite Springs:

A basic primer on Fiber Reinforced Polymer (FRP) materials and their application
The core topic discussed is low profile, space efficient Chassis Systems driving the need for Transverse Composite Leaf Springs
Longitudinal leaf springs as commonly applied to light trucks and trailers - advantages are highlighted

Vehicle requirements will be rolled down to Subsystems and Components. At the component level the use of innovative, lightweight composite materials provides a significant advantage. Besides ensuring technical feasibility, implementation on high volume production vehicles is essential for competing with aluminum and steel materials. Within suspension, Carbon Fiber Reinforced Polymer (CFRP) suspension links as well as lateral and longitudinal leaf springs made from Glass Fiber Reinforced Polymer (GFRP) materials are capable solutions. The low mass offered by composite materials when applied to the unsprung portion of the suspension contributes to improved Vehicle handling and ride dynamics.

Based on the experience of the successful implementation of the GFRP transverse leaf springs for the Volvo Scalable Product Architecture (SPA) platform, the paper will discuss recent developments in composite leaf springs:

Design for a progressive longitudinal leaf spring made more efficient by eliminating multiple steel leaves in favor of a more efficient single-leaf structure in GFRP
Holistic approach to the GFRP leaf spring development process focusing on material characterization, simulation, manufacturing and component testing
Adjustable Height Suspension with a proposed low mass and low cost mechanization

The paper focuses on a detailed look at evolving Vehicle architectures including new and innovative solutions. The paper discusses only proposed Engineering solutions; it does not comprehend or imply supplier relationships and/or legal assessments.

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Composite Suspension Leaf Springs: The Smart Solution 2020-01-0991

SAE MOBILUS