Singh, International Journal of Advanced Engineering Research and Studies E-ISSN2249–8974 Review Article GENERAL REVIEW OF MECHANICAL SPRINGS USED IN AUTOMOBILES SUSPENSION SYSTEM Niranjan Singh Address for Correspondence Department of Mechanical Engineering Model Institute of Engineering & Technology, Kot Bhalwal, Jammu, J&K (India) ABSTRACT The main functions of automobile suspension systems are to isolate the structure and the occupants from shocks and vibrations generated by the road surface. The suspension systems basically consist of all the elements that provide the connection between the tyres and the vehicle body. A spring is an elastic object used to store mechanical energy. It is an elastic body that can be twisted, pulled, or stretched by some force. It can return to their original shape when the force is released. It is a flexible element used to exert a force or a torque and, at the same time, to store energy. The force can be a linear push or pull, or it can be radial, acting similarly to a rubber band around a roll of drawings. The torque can be used to cause a rotation. The main objective of this research paper is to through some light on the fatigue stress analysis of springs used in automobiles. Theoretical, Numerical and Experimental methods are used for the analysis of springs but Finite Element Method is the best for its analysis and calculating the fatigue stress, life cycle and shear stress springs. KEY WORDS: Suspension system , helical compression spring, leaf spring, Maximum shear stress, Deflection, fatigue stress, Finite element method. 1. INTRODUCTION: lateral (cornering) forces, and braking and driving Suspension systems have been widely applied to torques. vehicles, from the horse-drawn carriage with flexible • Resist roll of the chassis. leaf springs fixed in the four corners, to the modern • Keep the tires in contact with the road with automobile with complex control algorithms. The minimal load variations suspension of a road vehicle is usually designed with To accomplish all functions, the suspension system two objectives; to isolate the vehicle body from road requires an elastic resistance to absorb the road irregularities and to maintain contact of the wheels shocks and this job is fulfilled by the suspension with the roadway. Isolation is achieved by the use of springs [2] . A spring is defined as an elastic machine springs and dampers and by rubber mountings at the element, which deflects under the action of the load connections of the individual suspension & returns to its original shape when the load is components. From a system design point of view, removed [3] . Mechanical springs are used in machine there are two main categories of disturbances on a designs to exert force, provide flexibility, and to store vehicle, namely road and load disturbances. Road or absorb energy. Springs are manufactured for many disturbances have the characteristics of large different applications such as compression, extension, magnitude in low frequency such as hills and small torsion, power, and constant force. Depending on the magnitude in high frequency such as road roughness. application, a spring may be in a static, cyclic or Load disturbances include the variation of loads dynamic operating mode. A spring is usually induced by accelerating, braking and cornering. considered to be static if a change in deflection or Therefore, a good suspension design is concerned load occurs only a few times, such as less than with disturbance rejection from these disturbances to 10,000 cycles during the expected life of the spring. the outputs. Roughly speaking, a conventional A static spring may remain loaded for very long suspension needs to be “soft” to insulate against road periods of time. The failure modes of interest for disturbances and “hard” to insulate against load static springs include spring relaxation, set and creep. disturbances. Therefore, suspension design is an art The main objectives of spring are as follows: of compromise between these two goals (Wang • To apply force: A majority industrial, e.g. To 2001).Today, nearly all passenger cars and light provide the operating force in brakes and trucks use independent front suspensions, because of clutches, to provide a clamping force, to provide [1] the better resistance to vibrations . The main a return load, to keep rotational mechanisms in functions of a vehicle’s suspension systems are to contact, make electrical contacts, counterbalance isolate the structure and the occupants from shocks loading, etc. and vibrations generated by the road surface. The • To control motion: Typically storing energy, suspension systems basically consist of all the e.g. wind-up springs for motor, constant torque elements that provide the connection between the applications, torsion control, position control, tires and the vehicle body. The suspension system etc. requires an elastic resistance to absorb the road • To control vibration : used in essence for noise shocks and this job is fulfilled by the suspension and vibration control, e.g. flexible couplings, springs. According to Gillepsie (1992), the primary isolation mounts, spring and dampers, etc. functions for suspension systems are; • To reduce impact: Used to reduce the • Provide vertical compliance so the wheels can magnitude of the transmitted force due to impact follow the uneven road, isolating the chassis from or shock loading, e.g. buffers, end stops, bump roughness in the road. stops etc. • Maintain the wheels in the proper steer and In practical situations, springs are used to provide camber attitudes to the road surface. more than one of the above functions at the same • React to the control forces produced by the tires- time. Because of superior strength and endurance longitudinal (acceleration and braking) forces, characteristics under load, most springs are metallic. Int. J. Adv. Engg. Res. Studies/III/I/Oct.-Dec.,2013/115-122 Singh, International Journal of Advanced Engineering Research and Studies E-ISSN2249–8974 However, other resilient materials, e.g. polymers, n = No. of active coils, where special properties such as a low modulus and G = Modulus of rigidity for the spring material, high internal damping capacity are required F = Axial load on the spring, 2. CLASSIFICATION OF SPRING: = Max. shear stress induced in the wire, 2.1. Leaf spring: Fig.1 shows the plate spring or leaf C = spring index = D/d spring in which the major stresses are tensile and P= Pitch of the coils, and compressive. Leaf springs may be of cantilever type δ = Deflection of the spring, as a result of an axial or semi elliptical or elliptical. A leaf spring consists load F. of flat leaves or plates of varying lengths clamped together so as to obtain greater efficiency and resilience. (a) (b) Fig.1 Leaf spring Fig. 5(a) Helical spring with axial load and (b) free body 2.2. Cylindrical helical spring: Fig.2 shows diagram. cylindrical helical spring which may be in If we remove a portion of the spring, the internal compression or tension. The major stresses reactions will be a direct shear and a torque T = F× produced in this are shear due to twisting. The load D/2 where each will cause a shear stress, and the applied is parallel to the axis of spring. The cross- maximum shear will occur at the inner surface of the section of the wire may be round, square or wire which is equal to: rectangular. These springs are wound in the form of ͕ͬ͡ = ͎ͦ/̈́ + ̀/̻ a helix of a wire. Substituting T= F× D/2, r= d/2, ̈́ = π/32 d 4,A= π/4 d 2; gives ͬFD ͨF = ƍ π Βw π Βv Defining the spring index which is a measure of coil curvature as: Fig.2. (a) Fig.2. (b) C = spring index = D/d, for most springs C ranges Fig.2. (a) & (b) Cylindrical conical spring from 6 to 12 2.3. Helical conical spring: The fig.3 is shown a We get: helical conical spring. The major stresses produced ͦͮͥ ͬ ͬ = ʚ ʛ= K in this are also shear due to twisting. If the radius of ͦ π Βw s π Βw vü~u the coils of a helical spring is constant, then it Ks Ɣ vü ; becomes a cylindrical helical. If a helical spring where K s is called the “Shear stress correction factor” works in torsion, i.e. the torsional moment is applied This equation assumes the spring wire to be straight about the axis of the helix, then the spring obtained and subjected to torsion and direct shear. However, is helical torsion spring. Major stresses produced in the wire is curved and the curvature increases the this spring are tensile and compression due to shear stress and this is accounted for by another bending. correction factor K C and thus the equation becomes: 3 = K c Ks 8̀̾/ π d Where Kc is the “curvature correction factor”. Or easier the two correction factors are combined together as a single correction factor K B where: ͨͮͦ (a) (b) (c) K = K ×K = B c s ͨͯͧ Fig.3 (a), (b) & (c). Helical conical spring ͬ Thus, = K 2.4. Spiral spring : If the angle of helix is zero as B πΒw shown in fig.4, then it is a spiral spring, consists of a 3.1. Deflection of Helical Springs: flat strip wound in the form of a spiral and loaded in The deflection-force relation can be obtained using torsion. The major stresses produced in this are Castigliano's theorem. The total strain energy in the tensile and compression due to bending by load. spring wire has two components torsional and shear. v v U = + ͦ ͦ Substituting for T, A & J and knowing that L= πDN Where N = N a is the Number of active coils , we get: ͨvw ͦ v U= x Ā + v (a) (b) Applying Castigliano's theorem to get the deflection Fig.4 (a) & (b) Spiral spring [4] “δ”; i4 ͬw ͨ 3.