Development of a Lightweight CFRP Coil Spring

Daewon Jang; Sungbae Jang

doi:10.4271/2014-01-1057

Today, all manufacturers of vehicles are up for the challenge to abide in automobile emission control laws. Weight reduction is one of the best solutions to reduce both fuel consumption and emissions.

The most effective method for the said idea is to have lightweight materials to some parts of vehicle using the FRP(Fiber Reinforced Plastics). In order to obtain good mechanical properties of FRP, continuous fiber should be used. But it is difficult to design and manufacture FRP parts using continuous fiber because of material properties and molding process.

In this paper, it is used CF(carbon Fiber) and Epoxy to make a composite material. Properties of this CFRP can be predicted through analysis. Tests and simulations of specimen are performed as every step progresses for correlation. A spring can be designed to meet all requirements for specific performance. The CFRP spring is made by new devices and methods and can be applied to vehicle for practical use. Patents regard to this devices were registered. This CFRP coil spring have done tests for reliability. As a result, weight can be reduced by 70% and ultra-lightweight CFRP coil spring are used in all process, from design to vehicle evaluation.

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Development of a Lightweight CFRP Coil Spring 2014-01-1057

SAE MOBILUS