Development of light-weighting springs

Abstract

This project focuses on the development of lightweight spring using a hybrid material composition of nylon and carbon fiber. The study encompasses two distinct materials: pure nylon and 15% carbon fiber with nylon. These springs are designed using a 3D CAD modelling software SOLIDWORKS and are manufactured utilizing advanced 3D printing technology, which enables the intricate layer-by-layer construction of complex geometries. The primary objective is to investigate the mechanical behavior and performance of these springs through compression and tensile testing, incorporating both experimental and numerical analyses. By combining nylon with carbon fiber, the aim is to achieve a balance between lightweight design and enhanced mechanical properties. Carbon fiber's exceptional strength-to-weight ratio and nylon's flexibility synergize to potentially create springs that are not only lightweight but also resilient under various loading conditions. The utilization of a 3D printer facilitates the precise fabrication of these intricate spring designs, ensuring consistent quality and geometry adherence. The research methodology involves conducting tensile tests on both nylon and 15% carbon fiber specimen and compression tests on both types of springs, pure nylon, and the nylon-carbon fiber composite. This was followed by a thorough numerical simulation analysis using ANSYS. In case of tensile testing, pure nylon exhibited average stress values and Young’s modulus values more than 15% carbon fiber spring. The numerical analysis, using finite element simulations, validated the experimental findings and provided a deeper understanding of the stress distribution and deformation behavior in the springs. In case of compression testing, pure nylon exhibited average (of all samples) more resistance values compared to 15% carbon fiber spring. ANSYS gave close values which validated the experimental findings. 15% carbon fiber spring and specimen were subjected to heat treatment as well and in both cases, properties such young’s modulus and force recorded after heat treatment were higher than before heat treatment. The nylon, compared to 15% carbon fiber spring showed better stiffness and strength properties.