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.
Keywords: 3D printing; automotive; carbon PEEK; composite materials; design; finite element analysis (FEA); leaf spring; optimization.