9 th INTERNATIONAL CONGRESS of Spring Industry. NEW CONCEPT FOR COMPOSITE COMPRESSION SPRINGS by

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1 9 th INTERNATIONAL CONGRESS of Spring Industry Taormina, Italy NEW CONCEPT FOR COMPOSITE COMPRESSION SPRINGS by, Jorge Llimpe, Stefan Titze, Ulf Kletzin, Department of Mechanical Engineering, Technische Universität Ilmenau, Germany Campus of TU Ilmenau Stephan Pöhler Martirich@TU-Ilmenau.de 03677/ TU Ilmenau - Germany WB

2 NEW CONCEPT FOR COMPOSITE COMPRESSION SPRINGS AGENDA 1. Introduction to composite springs 2. Theoretical description 3. Development of a manufacturing method 4. Comparison of theoretical and practical results 5. Conclusion and Outlook Page 1

3 NEW CONCEPT FOR COMPOSITE COMPRESSION SPRINGS AGENDA 1. Introduction to composite springs 2. Theoretical description 3. Development of a manufacturing method 4. Comparison of theoretical and practical results 5. Conclusion and Outlook Page 2

4 1. Introduction to composite springs Composite production (in general) [1] Leaf spring [2] Layering / Shaping / Fibers Matrix Laminate (ply) Pressing / Curing Composite Meander spring [2] [3] Bellow spring [4] Disc spring [4] Power spring [5] Spiral spring [6] Page 3

5 1. Introduction to composite springs C-spring [7] [8] Helical compression spring [9] [10] Summary composite springs + investigated and used for over 50 years + excellent spring characteristics + corrosion resistance, internal damping, fatigue behaviour + lightweight design + functional integration - expensive moulds - slow manufacturing (handwork, curing time) - often high safety factors Page 4

6 1. Introduction to composite springs Motivation Fiber composites represent excellent spring materials: very good mechanical and chemical properties at low density various types of fibers (textiles) and matrix materials available redundant fatigue behaviour (detectable) local layup adaptions for precise adjustment of characteristics Calculation? Manufacturing? Why should a new composite compression spring be developed? compression springs are frequently used simple shape for easier and cost efficient production usage of common (flat) textile fabrics various possibilities (parameters) for adjusting the spring curve The composite volute spring with rectangular cross section is a suitable solution for the demands! Page 5

7 NEW CONCEPT FOR COMPOSITE COMPRESSION SPRINGS AGENDA 1. Introduction to composite springs 2. Theoretical description 3. Development of a manufacturing method 4. Comparison of theoretical and practical results 5. Conclusion and Outlook Page 6

8 2. Theoretical description of the volute spring Spring curve linear part According to [11], the force-displacement-curve is linear for s 0,6 s c : F = q 3 2 G b t 3 π n f r K1 +r Kn r 2 K1 +r Kn 2 s with q 3 = β t 0,63 3 β t and β t = b/t G shear modulus b strip width t strip thickness n f number of active coils [11] TU Ilmenau - Germany Page

9 2. Theoretical description of the volute spring Spring curve non-linear part For s > 0,6 s c the number of active coils n f reduces, the characteristic becomes non-linear (progressive): F = q 3 π r Kx G b t 3 2 n f r K1 +r Kn s with r Kx = r Kn + m (r K1 r Kn ) and 1 m 0 for segmentation into intervals. This approach can be used to analyze a spring that is known in its dimensions. A dimensioning (design) on this basis is not possible due to the numerous parameters to be determined. Evaluation of test designs [11] TU Ilmenau - Germany Page

10 2. Theoretical description of the volute spring Mechanical properties of the composite The strip material of the spring is basically loaded by a torsion moment M t, which results from the force. Therefore, the shear modulus G has to be considered. F Composite strips consist of several layers with possible variations in fiber orientation, thickness, fiber material, etc. For complex layups, a common procedure is the calculation of the engineering constants, based on the Classical Laminate Theory (CLT). M t Simplification M t Otherwise, test specimen can be produced for more accurate input values. Page 9

11 2. Theoretical description of the volute spring Spring examples - Mechanical properties of the composite In this example, the engineering constants are calculated with the Excel-sheet AlfaLAM [12] Input values: 8 layers of E-glass fibers with epoxy matrix Fiber orientation 45 and - 45 (symmetrical) Fiber volume content φ = 0,4 (medium value) Output values: Stiffness matrix and flexibility matrix of composite Strain and stress (layer wise) Coefficients for engineering Page 10

12 Force [N] 2. Theoretical description Spring examples glass fibers [11] Spring 1 b = 40 mm t = 1,52 mm n f = 3 r K1 = 28,5 mm r K3 = 21 mm L 0 = 100 mm G = 8674 N/mm² Spring 2 b = 32 mm t = 0,75 mm n f = 3,5 r K1 = 17,8 mm r K3,5 = 13,5 mm L 0 = 105 mm G = 8674 N/mm² Calculation of glass fiber volute springs Spring1_Calc_linear Spring1_Calc_nonlinear Spring2_Calc_linear Spring2_Calc_nonlinear Displacement [mm] Page 11

13 NEW CONCEPT FOR COMPOSITE COMPRESSION SPRINGS AGENDA 1. Introduction to composite springs 2. Theoretical description 3. Development of a manufacturing method 4. Comparison of theoretical and practical results 5. Conclusion and Outlook Page 12

14 3. Development of a manufacturing method Preparation Manufacturing a winding core Preparation of a carrier film Pre-cutting fibers/textiles Lamination Fiber layering Wetting with resin Winding Winding from inner to outer diameter Curing (tempering) Postprocessing Releasing from core Removing carrier film Grinding / cleaning Winding technology Page 13

15 3. Development of a manufacturing method Testing the manufacturing method Glass fibers Carrier film Winding Finishing Demoulding Page 14

16 NEW CONCEPT FOR COMPOSITE COMPRESSION SPRINGS AGENDA 1. Introduction to composite springs 2. Theoretical description 3. Development of a manufacturing method 4. Comparison of theoretical and practical results 5. Conclusion and Outlook Page 15

17 Force [N] 4. Comparison of theoretical and practical results Measurements of spring characteristics glass fibers Spring 1 b = 40 mm t = 1,52 mm n f = 3 r K1 = 28,5 mm r K3 = 21 mm L 0 = 100 mm G = 8674 N/mm² Spring 2 b = 32 mm t = 0,75 mm n f = 3,5 r K1 = 17,8 mm r K3,5 = 13,5 mm L 0 = 105 mm G = 8674 N/mm² Comparison Measurements of calculated - Glass fiber and springs measured forces - Glass fiber springs - Spring1_Calc_linear Spring1_#1 Spring1_Calc_nonlinear Spring1_#1 Spring1_#2 Spring1_#2 Spring1_#3 Spring1_#3 Spring2_Calc_linear Spring2_Calc_nonlinear Spring2 Spring Displacement [mm] Page 16

18 Force [N] 4. Comparison of theoretical and practical results Measurements of spring characteristics carbon fibers Spring 1 b = 40 mm t = 1,32 mm n f = 3 r K1 = 28,5 mm r K3 = 21 mm L 0 = 100 mm G = N/mm² Spring 3 b = 11 mm t = 1,32 mm n f = 3,25 r K1 = 19 mm r K3,5 = 15,5 mm L 0 = 100 mm G = N/mm² (+20 /-20 layup) Comparison Measurements of calculated - Carbon fiber and measured springs forces - Carbon fiber springs Spring1_Calc_linear Spring1_#1 Spring1_Calc_nonlinear Spring1_#1 Spring1_#2 Spring1_#2 Spring1_#3 Spring1_#3 Spring3 Spring3_Calc_linear Spring3_Calc_nonlinear Displacement [mm] Page 17

19 Spring rate [N/mm] 4. Comparison of theoretical and practical results Comparison of calculated spring rates 5 4,5 4 3,5 3 2,5 Comparison of spring characteristics GF_Spring1_linear GF_Spring1_nonlinear GF_Spring2_linear GF_Spring2_nonlinear CF_Spring1_linear CF_Spring1_nonlinear CF_Spring3_linear CF_Spring3_nonlinear 2 1,5 1 0, Displacement [mm] Page 18

20 4. Comparison of theoretical and practical results Simplified comparison to helical compression springs (steel wire) Composite springs are not competitive in case of these properties The composite springs are not optimized Other advantages have to be considered for the choice of composite materials functional integration of damping characteristics (replacement of springdamper-units for example) Productivity : * According to DIN composite: about 1 per mould in 4-12 hours, with tempering, depending on matrix - steel springs: several per second Spring 1 Helical spring* Spring 1 Helical spring* Glass fiber Spring Steel Wire Carbon fiber Spring Steel Wire d mm - 1,25-2,00 b mm t mm 1,52-1,32 - n f 3 18,5 3 8,5 r min mm r max mm 28,5-28,5 - D m mm L 0 mm , L n mm ,6 R linear N/mm 1,35 1,37 2,50 2,44 F n N 80 87, G N/mm² Weight g 70,5 6,2 49,3 16,4 Material costs < 5 << 1 < 10 << 1 Page 19

21 Spring rate R [N/mm] [N/mm] Weight m m [g] 4. Comparison of theoretical and practical results Simplified comparison to volute springs (steel strip) Spring1 dimensions b = 40 mm t = variable n f = 3 n t = 5 r K3 = 21 mm r K1 = variable a = 0,1 mm Comparison by spring rate R Steel CFRP GFRP ρ [g/cm³] 7,90 1,42 1,74 G [GPa] 70,0 24,3 8,7 R [N/mm] 2,33 2,23 2,24 t [mm] 0,85 1,25 1,90 m [g] R test [N/mm] - 2,5 1,35 t test [mm] - 1,32 1,52 m test [g] - 49,3 70, significant advantages for fiber materials good accordance to the weight of the test springs Material comparison R steel R CFRP R GFRP m R steel R m CFRP R m GFRP m steel m CFRP m GFRP Page 20 linear calculation 0 0 0,0 0,5 1,0 1,5 2,0 2,5 3,0 Strip thickness t [mm]

22 NEW CONCEPT FOR COMPOSITE COMPRESSION SPRINGS AGENDA 1. Introduction to composite springs 2. Theoretical description 3. Development of a manufacturing method 4. Comparison of theoretical and practical results 5. Conclusion and Outlook Page 21

23 5. Conclusion and Outlook Conclusion - Composite springs have various advantages - Composite volute spring was not tested and used so far - Existing theoretical description can be used in first proximity - Mechanical properties can be calculated by common theories - Manufacturing method was developed and successfully approved - Measurements of force-displacement-curves have shown a good comparability to calculated curves for both glass and carbon fiber composites - Almost linear spring characteristics, no fatigue up to the block length, no setting - Simplified comparison to helical steel wire springs shows disadvantages in weight but significant advantages by comparing volute springs TU Ilmenau - Germany Page

24 5. Conclusion and Outlook Outlook - Adjustment of spring characteristics by several parameters (layup, fiber orientation, coil distance) - Testing different load cycles and fatigue properties - Investigations on frictional behaviour and damping - Improved production / automation - FEM-simulations for layer wise stress/strain/fatigue analysis - TU Ilmenau - Germany Page

25 Thank you for your kind attention! M. Sc. Phone: +49 (0) Research Group Wire and Springs Max-Planck-Ring 12 Werner-Bischoff-Bau WBB Ilmenau Germany Page 24

26 Ressources [1] R&G Faserverbundwerkstoffe GmbH: Composite materials handbook ; URL: Waldenbuch, 2009 [2] Stimpfl, J.: Leichtbau in faserverstärktem Kunststoff für Fahrwerksfedern im Automobil ; VDFI Lecture event Federn aus faserverstärkten Kunststoffen, Siegen, [3] DANTO-Invention GmbH & Co. KG: DANTO Feder ; URL: produkt/feder-aus-faser-kunststoff-verbunden/ /l161872; last visit: [4] Hufenbach, W.; Werner, J.; Körner, I.; Köhler, C.: Neuartige Leichtbaufedern in Faserverbundbauweise Bauweisen / Auslegung / Fertigung ; Ilmenauer Federntag; 2010 [5] Scharr, G.: Faserverstärkte Kunststoffe Federwerkstoffe für den Leichtbau ; VDI-Berichte Nr. 1972; 2006 [6] Zemann, R.: Federleicht ; URL: last visit: [7] Otto Bock Healthcare Deutschland GmbH: C-Walk Prothesenfuß 1C40 ; URL: last visit: [8] Michel, S.: Schneckenblattfeder ; URL: last visit: [9] Sardou SA: Helical coil springs ; URL: last visit: [10] Leichtbauzentrum Sachsen GmbH: Schraubendruckfeder aus Faserverbundkunststoff ; URL: last visit: [11] Meissner, M.; Schorcht, H.-J.; Kletzin, U.: Metallfedern ; 3. Auflage, Springer Vieweg, 2015 [12] Weber, T.: AlfaLam ; Excel-sheet Version 1.3.1; URL: last visit: Page 25

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