Projects & Dissertations
Finite element modeling, materials characterization, and structural optimization projects completed during M.Tech and B.Tech degrees. Full original PDF reports available for direct download.
Multi-Domain Optimization of Automotive Leaf Springs
Via Structural Geometry, Joint Architecture, and Hybrid Material Integration (Carried out at LTTS)
Problem Statement & Methodology
Automotive leaf spring suspensions are traditionally manufactured using structural 65Si7 spring steel, which contributes significant unsprung mass to the vehicle. This research investigated the multi-domain optimization of leaf springs by simultaneously varying cross-sectional taper, eye-joint architecture, and composite materials (E-glass/epoxy, S-glass/epoxy, Carbon/epoxy, and hybrid sandwich topologies).
A total of 75 distinct geometric and material configurations were modeled and simulated using 3D finite element analysis (FEA). Structural stiffness, Von Mises stress, maximum vertical deflection, and natural frequencies were evaluated against the baseline steel reference, followed by a formal Weighted Pugh Decision Matrix.
| Architecture | Material Stack | Mass | Max Stress | Max Deflection | Selection Rank |
|---|---|---|---|---|---|
| Baseline Multi-Leaf | Conventional 65Si7 Steel | 22.4 kg | 648 MPa | 98.2 mm | Datum Reference |
| Mono-Leaf Tapered | E-Glass / Epoxy | 11.8 kg (-47%) | 412 MPa | 132.4 mm | Rank 3 (High Deflection) |
| Mono-Leaf Constant | Carbon / Epoxy | 8.2 kg (-63%) | 520 MPa | 76.0 mm | Rank 2 (High Cost) |
| Hybrid Sandwich (Selected) | S-Glass / Epoxy + Steel Core | 16.1 kg (-28%) | 394 MPa | 59.0 mm | Rank 1 (Optimal Trade-off) |
Effect of Laser Shock Peening on ZE41 Mg Alloy
Microstructural Analysis and Mechanical Property Enhancement (Guide: Dr. Dinesh Babu P)
ZE41 is a lightweight magnesium-zinc-rare-earth alloy widely used in aerospace and automotive powertrain enclosures. However, its low yield strength and surface fatigue limits require post-processing improvements.
This project investigated Laser Shock Peening (LSP) without coating using a pulsed Nd:YAG laser (1064 nm). The high-energy shock waves induced severe plastic deformation and deep compressive residual stresses, suppressing surface micro-crack initiation.
PLA Reinforced Coir Fibre Composite via Stir Casting
Mechanical Property Characterization for Biodegradable Lightweight Applications
Fabricated eco-friendly composites by reinforcing a biodegradable Polylactic Acid (PLA) matrix with chemically treated natural coconut coir fibers. An alkaline NaOH surface treatment was carried out to eliminate wax, lignin, and hemicellulose, significantly improving interfacial bonding between natural fibers and polymer matrix.
Composite specimens were prepared using a modified stir-casting method and subjected to standardized mechanical testing: Tensile Strength (ASTM D638), Flexural Modulus (ASTM D790), and Izod Impact Strength (ASTM D256).