Imperial Journal of Interdisciplinary Research (IJIR) Vol-3, Issue-4, 2017 ISSN: 2454-1362, http://www.onlinejournal.in
Design of Helical Spring Suspension
Ragupathi.P1, Dhayanidhi. E2, Arunachalam. S3, Jegadeshwaran. A4, 5 Kamal Hassan. P 1Asst.Professor, Department of Mechanical Engineering, Muthayammal Engineering College, Rasipuram, Namakkal (D.T), TamilNadu 2, 3, 4,5UG Students, Department of Mechanical Engineering, Muthayammal Engineering College, Rasipuram, Namakkal (D.T), TamilNadu
Abstract-In a Vehicle; problems were happen while or luggage from damage and wear. The design of driving on bumping road condition. The prime front and rear suspension of a car may be moto of this paper is to model and analyze the differentia coil spring, also known as a helical performance of shock absorber by changing the spring, is a mechanical device which is typically wire diameter and material of the coil spring. The used to store energy and subsequently release it, to shock absorbers duty is to absorb or dissipate absorb shocks, or to maintain a force between energy. It reduces the effect of travelling over contacting surfaces. They are made of an elastic rough ground, leading to improved ride quality and material formed into the shape of as helix which increase in comfort due to substantially reduced returns to its natural length when unloaded. Under amplitude of disturbance. When a vehicle is riding tension or compression, the material of a coil on a level road and the wheels strikes a bump, then spring undergoes torsion. The spring characteristics the spring compressed quickly. The compressed therefore depend only on its shears modulus not on spring will regain its original length and causing its young’s modulus. the body to be lifted. Then the weight of vehicle will A coil spring may also be used as a torsion then push the spring down below its normal loaded spring in this case the spring as a whole is height. This in turns causes the spring to rebound subjected to torsion about its helical axis. The again. This process occurs over and over by each material of the spring is thereby subjected to a time, until the up and down movement stops. bending moment, either reducing or increasing the Hence, the spring design in a suspension system is helical radius. In this mode, it is the young’s utmost crucial. The analysis is performed by modulus of the material. Some types of coil spring considering the mass of Hybrid vehicle car and are tension or extension spring, compression coil with person seated on it. This Hybrid vehicle car is spring, volute spring, and Torsion spring. The made by our team for a challenge organized by tension coil springs, are designed to resist Imperial Society of Innovative Engineers stretching. They are usually having a hook or eye (ISIE).The comparison is done by changing the form at the each end for attachment. The wire diameter of the coil spring to check the best compression coil spring, are designed to resist dimension for the spring in shock absorber. being compressed. A typical use for compression Keywords: Shock Absorber, Helical Spring, coil springs is in car suspension system. The Volute Deflection, Analysis, Creo Parametric 3.0, ANSYS springs are used as heavy load compression Workbench 14.5 springs. A strip of plate is rolled into the shape of both helix and a spiral. When compressed, the strip I.INTRODUCTION is stiffer edge on than a wire coil, but the spiral arrangement allows the turns to overlap rather than bottoming out an each other. The torsion spring, Suspension is the system of tires, tire air, are designed to resist the twisting actions. Often springs, shock absorbers and linkages that connects associated to clothes pegs or up and over garage a vehicle to its wheels and allows relative motion doors. Creo is a family of design software between the two. This system us support both road supporting product design for discrete holding or handling and ride quality, which are at manufacturers and is developed by PTC. The suite odds with each other. The tuning suspension consist of apps, each delivers a distinct set of involves finding the right compromise. It is capabilities for a user role within product important for the for the suspension to keep the development. It runs on Microsoft Windows and road wheels in contact with the road surface as provides application for 3D CAD parametric much as possible, because all the road or ground features solid modeling, 3D Direct modeling, 2D forces acting on the vehicle do so through the orthographical Views, Finite Element Analysis and contact patches of the vehicle itself and any cargo its Simulation, Schematic Design, Technical
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Imperial Journal of Interdisciplinary Research (IJIR) Vol-3, Issue-4, 2017 ISSN: 2454-1362, http://www.onlinejournal.in
Illustrations, and Viewing and Visualizing.Creo individual elements to the linked system. When the elements and Creo parametric compete directly effects of loads and boundary conditions are with CATIA, Siemens NX/Solid edge and Solid considered, a set of linear or nonlinear algebraic works. The creo suite of application replaces and equations is usually obtained. Solution of these supersedes PTC’s Products formerly known as Pro equations gives the approximate behavior of the ENGINEERS, CoCreate, and product View. It has continuum or system. The continuum has an many software package solutions and features. By infinite number of degrees of freedom (DOF), using the software Creo Parametric 3.0 we have while the discredited model has a finite number of designed the 3D solid model and spring. When DOF. This is the origin of the name, finite element compared to other 3D modeling software Creo 1.1 OBJECTIVE parametric is easy to design and for assembly The objective of the work is as follows: process. The detailed view is shown in fig.1 and 2. 1. The selection of material for helical spring suspension. 2. To construct the suitable helical spring suspension for a comfort driving. 3. To determine the maximum stress and deflection.
II. LITRETATURE REVIEW
For providing the best design of spring coil for the suspension system of Hybrid Vehicle Fig 1. Spring Model car, a lot of technical papers and journals were studied. The following list presents the grids of main papers which are referred throughout the project duration. K.Vinay Kumar et.al [1] used three different materials like alloy steel, chromium vanadium steel; stainless steel was used with a constant load of 850N. Among the above materials alloy steel material gave the better stress and deformation values. Mostly prefer alloy steel Fig 2. Spring with Shock Absorber material for bike suspension spring due it its material stability and ductility by observing those Many problems in engineering and analysis stress and deformation values. Alloy steel applied science are governed by differential or material is staying stable up to load 2550N. Later, integral equations. The solutions to these equations by increasing loads the stress was crossing the would provide an exact, closed form solution to the yield strength of the material due to that the particular problem being studied. However, breaking of spring will be takes place. Therefore, complexities in the geometry, properties and in the from the above practical result alloy steel material boundary conditions that are seen in most real is more stable and gives good efficiency compared world problems usually means that an exact to other two materials. solution cannot be obtained in a reasonable amount of time. They are content to obtain approximate Prince Jerome Christopher et.al. [2] solutions that can be readily obtained in a designed a Shock Absorber used for 160 cc bike reasonable time frame and with reasonable Effort. and they have modeled it by using 3D parametric The FEM is one such approximate solution software, Pro/Engineer. The shock absorber design technique. The FEM is a numerical procedure for is modified by reducing the diameter and stress obtaining approximate solutions to many of the analysis is performed. The stress value is lesser in problems encountered in engineering analysis. In the designed spring then in original which adds an the FEM, a complex region defining continuums advantage to the design. By comparing the results discredited into simple geometric shapes called in the table they could analyze that the modified elements. The properties and the governing spring has reduced in weight and is safe. relationships are assumed over these elements and N.Lavanya et.al. [3] Discussed about the expressed mathematically in terms of unknown vonmises stress and strain induced in chromium Values at specific points in the elements called vanadium steel and low carbon structural steel in nodes. An assembly process is used to link the various condition. The total mechanical stress and
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Imperial Journal of Interdisciplinary Research (IJIR) Vol-3, Issue-4, 2017 ISSN: 2454-1362, http://www.onlinejournal.in
strain values obtained for chromium vanadium is 4. No.of.Turn n 9 best suitable for the production of helical spring 5. Pitch at start - 15 mm when compared with the low carbon structural 6. Pitch at end - 10 mm steel. 7. Pitch by value - 20 mm Logavigneshwaran et.al. [4] Redesigned that the stress acting on the shock absorber is reduced. The proposed redesign will reduce the 3.2 Theoretical Calculations: deformation an induced stress magnitude for the The sample calculation for the helical same applied loading conditions when compared spring is carried out for the various loading with the existing design. This in turns increases the condition and is tabulated below in table.2. life of shock absorber by reducing its failures. The analytical result conforms to the simulation result W = Load applied from the ANSYS. D = Mean diameter III.METHODOLOGY d = spring wire diameter 3.1 Design Procedure G = Modulus of rigidity The spring has been modeled by using Table.2 Different Loading Condition creo parametric 3.0, and analyzed by using ansys workbench 14.5.The helical spring has been Loads S.No. Condition designed by using options such as sketch, extrude, Kg N helical sweep these are been carried out in a single Chassis 1. 350 3432.3 part modeling and the assembly is done. Later on weight the solid model of helical spring is transferred to Entire ansys workbench in the format of (.iges). the 2. Weight 450 4413 defining of various process and parameters to the (fittings) component is carried out such as selection material, Weight with 3. 500 4903.3 meshing and its parameters, fixing the support, single person applying loads and finally the result was executed under these contrains.The spring description has been shown in fig. and the dimension is tabulated For Load = 3432.3N below in table.1. Spring Index (C) =
= ÷ 푑 = . ÷ . Shear Stress factor (K) =
=( − ÷ − ) + . ÷
( 푥 − ) ÷ ( 푥 − )
= + . ÷ Fig.3 Specification of spring Maximum . Shear Stress (τ) Table.1 Dimension for helical spring = S.No Dimension Symbol Value = 퐾 푥 푥 푊 푥 ÷ 휋 푥 푑 Wire 1. d 9.49 mm Diameter = . 푥 푥 . 푥 ÷ 휋 푥 . Coil Mean 2. D 56.94 mm Deflection (δ) Diameter . 푃푎 3. Coil Free Length l 152 mm = ( 푊 푥 푥 푥 ÷ 퐺 푥 푑 ) Imperial Journal of Interdisciplinary Research (IJIR) Page 1423
Imperial Journal of Interdisciplinary Research (IJIR) Vol-3, Issue-4, 2017 ISSN: 2454-1362, http://www.onlinejournal.in
= Strength 8. Specific Heat J/kg k 480 = ( . 푥 푥 푥 ÷ 푥 . ) Similarly, . 푚푚 theoretical calculation is carried out for Table.7 Properties of Chromium Vanadium AISI different loads and materials. The values obtained 6150 are tabulated as below in table.3, 4, and 5.
Table.3 for Stainless Steel S.No. Properties Units Values Maximum Load Deflection 3 S.no Shear Stress 1. Density Kg/mm 7.8e-6 (N) (δ) mm (τ) MPa 2. Young’s MPa 2.1e5 1. 3432.3 727.87 73.12 Modulus 2. 4413 935.84 94.01 3. Poisson Ratio - 0.29 3. 4903.3 1039.3 104.46 Bulk 4. MPa 1.6667e5 Table.4 for Chromium Vanadium AISI 6150 Modulus Maximum Shear Load Deflection 5. MPa 81395 S.no Shear Stress Modulus (N) (δ) mm (τ) MPa 1. 3432.3 727.87 69.10 Tensile Yield 6. Strength MPa 620 2. 4413 935.84 88.84 3. 4903.3 1039.3 98.72 Ultimate Table.5 for Low Carbon Steel AISI 1018 7. Yield MPa 940 Maximum Strength Load Deflection S.No. Shear Stress 8. Specific Heat J/kg k 450 (N) (δ) mm (τ) MPa 1. 3432.3 727.87 70.79 Table.8 Properties of Low Carbon Steel AISI 2. 4413 935.84 91.01 1018 3. 4903.3 1039.3 101.12 S.No. Properties Units Values
3.3 Material Properties: 1. Density Kg/mm3 7.87e-6 The mechanical properties such as density, 2. Young’s MPa 2.05e5 young’s modulus, and tensile strength, etc., for the Modulus materials Stainless steel, Chromium vanadium 3. Poisson Ratio 0.29 AISI 6150, and Low Carbon Steel AISI 1018 are Bulk 4. MPa 1.627e5 tabulated as below in table.6, 7 and 8 Modulus Shear Table.6 Properties for Stainless Steel 5. MPa 79457 Modulus Tensile Yield 6. MPa 370 S.No. Properties Units Values Strength Ultimate 7. Yield MPa 440 1. Density Kg/mm3 7.85e-6 Strength 8. Specific Heat J/kg k - 2. Young’s MPa 2e5 Modulus 3. Poisson Ratio - 0.31 Bulk 3.4 Meshing View: 4. MPa 1.6667e5 Modulus Meshing is most important part in any of Shear 5. MPa 76923 the simulations because it can only show the drastic Modulus changes in result. Here we have used triangular Tensile Yield 6. MPa 250 mesh which will provide the result with high Strength accuracy. The mesh view is shown in fig.4 and 5. Ultimate 7. MPa 460 The mesh properties are also tabulated for both in Yield table.9 and 10.
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Imperial Journal of Interdisciplinary Research (IJIR) Vol-3, Issue-4, 2017 ISSN: 2454-1362, http://www.onlinejournal.in
Table.9 Mesh Properties of Helical Spring Relevance 100 Statistics Nodes 9490 Elements 4407 Specific 1.2382 39.236 Mesh Ratio (min) (max) Metric Average 2.69210170183798 (Aspect Standard 1.8832048017774 Ratio) Deviation
Fig.4 Meshing View of spring Table.10 Mesh Properties of Helical Spring of Shock Absorber 100 Relevance Statistics Nodes 9075 Elements 4031 1.2235 22.956 Specific Mesh (min) (max) Ratio Metric Fig.6.a Maximum Deformation obtained for (Aspect Average 2.54458504093277 load 3432.3 N Ratio) Standard 1.50331732661413 Deviation
Fig.6.b Maximum Shear Stress Obtained for load 3432.3 N
Fig.5 Meshing View of spring with shock absorber 2) For load = 4413 N IV. RESULT AND DISCUSSION: 4.1 Simulations process: The simulation process for the helical spring and spring with shock absorber is carried out in ansys 14.5.Here, we have found the result Deformation and Stress for both the components under different loads i.e., for the chassis weight, Entire weight and the weight along with a single Fig.7.a Maximum Deformation obtained for person these defines the life and withstand load 4413 N capacity of the spring. These are shown in the chapter 4.1.1 and 4.1.2. 4.1.1. Simulation for Helical Spring (Deformation and Shear Stress): For Stainless Steel 1) For load = 3432.3 N
Fig.7.b Maximum Stress obtained for load 4413 N
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Imperial Journal of Interdisciplinary Research (IJIR) Vol-3, Issue-4, 2017 ISSN: 2454-1362, http://www.onlinejournal.in
3) For load = 4903.3 N
Fig.10.a Maximum Deformation obtained for load 4413 N Fig.8.a Maximum Deformation obtained for load 4903.3 N
Fig.10.b Maximum Stress obtained for load 4413 N Fig.8.b Maximum Stress obtained for load 4903.3 N 3) For load = 4903.3 N For Chromium Vanadium AISI 6150
1) For load = 3432.3 N
Fig.11.a Maximum Deformation obtained for load 4903.3 N
Fig.9.a Maximum Deformation obtained for load 3432.3 N
Fig.11.b Maximum Shear Stress obtained for load 4903.3 N
For Low Carbon Steel AISI 1018
1) For load = 3432.3 N Fig.9.b Maximum Shear Stress obtained for load 3432.3 N
2) For load = 4413 N
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Imperial Journal of Interdisciplinary Research (IJIR) Vol-3, Issue-4, 2017 ISSN: 2454-1362, http://www.onlinejournal.in
Fig.14.a Maximum Deformation obtained for Fig.12.a Maximum Deformation obtained for load 4903.3 N load 3432.3 N
Fig.14.b Maximum Shear Stress obtained for load 4903.3 N Fig.12.b Maximum Shear Stress obtained for load 3432.3 N 4.1.2. Simulation process for Helical Spring with Shock Absorber (Deflection 2) For load = 4413 N and Stress) For Stainless Steel 1) For load = 3432.3 N
Fig.13.a Maximum Deformation obtained for load 4413 N
Fig.15.a Maximum Deformation obtained for load 3432.3 N
Fig.13.b Maximum Stress obtained for load 4413 N
3) For load = 4903.N Fig.15.b Maximum Stress obtained for load 3432.3 N 2) For load = 4413 N
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Imperial Journal of Interdisciplinary Research (IJIR) Vol-3, Issue-4, 2017 ISSN: 2454-1362, http://www.onlinejournal.in
Fig.16.a Maximum Deformation obtained for Fig.18.a Maximum Deformation obtained for load 4413 N load 3432.3 N
Fig.16.b Maximum Stress obtained for load Fig.18.b Maximum Stress obtained for load 4413 N 3432.3 N 3) For load = 4903.3 N 2) For load = 4413 N
Fig.17.a Maximum Deformation obtained for Fig.19.a Maximum Deformation obtained for load 4903.3 N load 4413 N
Fig.19.b Maximum Stress obtained for load 4413 N Fig.17.b Maximum Stress obtained for load 3) For load = 4903.3 N 4903.3 N For Chromium Vanadium AISI 6150 1) For load = 3432.3 N
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Imperial Journal of Interdisciplinary Research (IJIR) Vol-3, Issue-4, 2017 ISSN: 2454-1362, http://www.onlinejournal.in
Fig.20.a Maximum Deformation obtained for load 4903.3 N
Fig.22.b Maximum Stress obtained for load 4413 N
Fig.20.b Maximum Stress obtained for load 3) For load = 4903.3 N 4903.3 N For Low Carbon Steel AISI 1018 1) For load = 3432.3 N
Fig.23.a Maximum Deformation obtained for load 4903.3 N
Fig.21.a Maximum Deformation obtained for load 3432.3 N
Fig.23.b Maximum Stress obtained for load 4903.3 N 4.2 Analytical Value of Helical spring Table.11 for Stainless Steel Maximum Loads Maximum S.No. Deformation (N) stress(τ) (δ) Fig.21.b Maximum Stress obtained for load 1. 3432.3 2.928 2.8664 2. 4413 3.7646 3.6855 3432.3 N 3. 4903.3 4.1829 4.095
2) For load = 4413 N Table.12 for Chromium Vanadium AISI 6150 Maximum Loads Maximum S.No. Deformation (N) stress(τ) (δ) 1. 3432.3 2650.4 2.8671 2. 4413 3407.7 3.6863 3. 4903.3 3786.3 4.0959
Table.13 for Low Carbon Steel AISI 1018
Fig.22.a Maximum Deformation obtained for load 4413 N
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Imperial Journal of Interdisciplinary Research (IJIR) Vol-3, Issue-4, 2017 ISSN: 2454-1362, http://www.onlinejournal.in
Maximum Loads Maximum 120 S.No. Deformation Stainless (N) stress(τ) 100 (δ) Steel 1. 3432.3 80 2.7151 2.8671 Chromium 60 2. 4413 3.4908 3.6863 Vanadium 40 AISI 6150 3. 4903.3 3.8787 4.0959 20 Low Carbon 0 Steel AISI 4.3 Analytical Value of Helical spring 3432.3 4413 4903.3 1018 with Shock Absorber Table.14 for Stainless Steel Fig.24 The theoretical values of Deformation is Maximum graphically plotted between Stainless Steel, Loads Maximum S.No. Deformation Chromium Vanadium AISI 6150 and Low (N) stress(τ) (δ) Carbon Steel AISI 1018 1. 3432.3 0.012556 40.047 4.5 Graph Plotting of Deformation for spring by using the Analytical Values 2. 4413 0.016042 60.091 for Stainless steel, Chromium Vanadium AISI 6150 and Low Carbon 3. 4903.3 0.017824 66.767 steel AISI 1018.
Table.15 for Chromium Vanadium AISI 6150 20 Low Carbon Maximum Loads Maximum Steel AISI S.No. Deformation 15 (N) stress(τ) 1018 (δ) Chromium 10 1. 3432.3 11.473 46.825 Vanadium AISI 6150 5 2. 4413 14.751 60.204 Stainless Steel 3. 4903.3 16.49 57.215 0 3432.3 4413 4903.3
Table.16 for Low Carbon Steel AISI 1018 Fig.25 The analytical values of Deformation for Maximum Loads Maximum spring is graphically plotted between Stainless S.No. Deformation (N) stress(τ) Steel, Chromium Vanadium AISI 6150 and Low (δ) Carbon Steel AISI 1018 1. 3432.3 0.011752 46.825 4.6 Graph Plotting of Stress for spring 2. 4413 0.11511 60.204 with shock absorber by using the Analytical Values for Stainless steel, 3. 4903.3 0.01678 66.893 Chromium Vanadium AISI 6150 and Low Carbon steel AISI 1018. 4.4 Graph Plotting of Deformation for Spring by using the Theorotical Values for Stainless steel, Chromium Vanadium AISI 6150 and Low Carbon steel AISI 1018.
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Imperial Journal of Interdisciplinary Research (IJIR) Vol-3, Issue-4, 2017 ISSN: 2454-1362, http://www.onlinejournal.in
[3] Prince Jerome Christopher.J, Pavendhan.R 250 “Design and Analysis of Two Wheeler Shock Absorber Low Coil Spr 200 ing”, International Journal of Modern Carbon Engineering Research (IJMER) Open Access [4] Mr. Harshad B. Pawar, prof. Amol R. Patil, Dr. 150 Steel AISI 1018 Sanjay B. Zope “Analysis and Optimization of a Helical Compression Coil Spring Used for TWV”, Vol -2 Issue – 100 Chromium 1 2016, IJARIIE-ISSN (O) -2395-4396 Vanadium [5] K.Vinay Kumar, R. Rudrabhhiramu “Design 50 and Analysis of Helical Springs in Two Wheeler AISI 6150 Suspension System”, Volume 5, Issue 2 DEC 2015, 0 International journal of Research 3432.3 4413 4903.3 [6] Satbeer Singh Bhatia, Ajeet bergaley, “Analysis of the Design of Helical Compression Spring to Study the Behavior of Steel and Composites Used as Fig.26 The analytical values of Stress for spring is Spring Materials”, ISSN: 2277-9655, Scientific Journal graphically plotted between Stainless Steel, Impact Factor: 3.449 (ISRA), Impact Factor: 1.852 Chromium Vanadium AISI 6150 and Low [7] Suresh Raddy, Thontaraj Urs T.S, Carbon Steel AISI 1018 “Comparative Study of Static Structural Analysis of a Shock Absorber for Different Material”, Vol.3, Issue 6, V.CONCLUSION November 2014 ISSN: 2319-5967 ISO 9001:2008 Certified IJESRIT Basically, In Spring it should withstand [8] N.Lavanya, P.Sampth Rao, M.Pramod Reddy, the load which is subjected to it.Then only the “Design and Analysis of a Suspension Coil Spring for system will be safe enough for the confort journey Automotive vehicle”, ISSN: 2248-9622. Vol.4, Issue in the wheel.So here in this we have compared the 9(Version 5), September 2014, pp.151-157. analytical result of Deformation and Stress for the material stainless steel, Chromium Vanadium AISI 6150 and Low Carbon Steel AISI 1018. i) Fig.25 shows the analytical result of deformation in the spring.The maximum deformation obtained for stainless steel is higher when compared with the Chromium Vanadium AISI 6150 and Low Carbon Steel AISI 1018. ii) Fig.26 shows the analytical result of Stress in the spring.The maximum stress obtained for different loading condition in Stainless Steel is higher and efficient when compared with stress obtained for Chromium Vanadium AISI 6150 and Low Carbon Steel AISI 1018. Finally, We have came to an conclude that by using the Stainless Steel in the spring, the withstanding capacity of it will be higher and more efficient for the domestic pyurpose.So that the journey will be more comfort in vehicle while riding on the bumped road. VI.REFERENCE
[1] Logavigneshwaran.S, Sriram.G, Arunprakash.R “Design and Analysis of Helical Coil Spring in Suspension System”, Volume 9 issue 1- September 2015 – ISSN: 2349-9303, International Journal for Trends in Engineering and Technology [2] C.Madan Mohan Reddy, D.Ravindra Naik, Dr.M.Lakshmi Kantha Reddy “Analysis and Testing of Two Wheeler Suspension Helical Compression Spring”, ISSN (e):2250-3021, ISSN (p):2278-8719 Vol.4, Issue 06 (June 2014).║VI║PP 55-60.IOSR Journal of Engineering (IOSRJEN)
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