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International Journal of Emerging Technology and Advanced Engineering

Website: www.ijetae.com ( ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 4, Issue 8, August 2014)

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Design Evaluation & Optimization of a Two-WheelerSuspension SystemSetty Thriveni 1, G. Ranjith Kumar 2, Dr. G. Harinath Gowd 3

1,2 PG Student, 3 Professor, Department of Mechanical Engineering, Madanapalle Institute of Technology & Science, Madanapalle. Andhra Pradesh., INDIA

Abstract-- A suspension system or shock absorber is amechanical device designed to smooth out or damp shockimpulse, and dissipate kinetic energy. In a vehicle, it reducesthe effect of t raveling over rough ground, leading to improvedride quality, and increase in comfort due to substantiallyreduced amplitude of disturbances. In suspension frameworkspring configuration is exceptionally paramount as it impactsthe riding consolation in a time of distress and in the generalweight of the vehicles. For the present work, the monosuspension system at present using in various two wheelers ischosen for study. The present work focuses mainly onobtaining the optimal spring dimensions without affecting theriding comfort for mono suspension system. To meet theabove objective, first the existing springs of Honda CBUnicorn & Yamaha FZ springs will be tested for its strengthby conducting the compression test. Later its 3D model drawnusing SOLIDWORKS will be imported to HYPERMESH formeshing the spring & to apply the required loads on it. Finallyby importing it into the ANSYS software to evaluate thestresses, strains and its load carrying capacity by doing staticanalysis. Mainly, this paper deals with the coil spring which is

used in the Mono Suspension system. Then further analysisusing the above softwares will be done by changing the springdimensions and by using alternate materials. Thereby theoptimal dimensions will be identified.

Keywords-- Ansys, Hyper mesh, Mono Suspension System,Optimization & Solid works.

I. I NTRODUCTION Suspension framework serves to store strain energy by

avoiding themselves when the wheels go over any knockout and about. As soon as the wheels go off the bump, thespring rebound back owing it their inherent elastic action.The automobile frame & body is attached to the front &rear axle by suspension system which minimizes the effectof road shocks transmitted to the frame, thus protecting thevarious working parts of the vehicle and the occupants of amotor vehicle. Suspension system consists of a spring & adamper (shock absorber). The theoretical calculations aregiven below.Material: Spring SteelConsider, Weight of the bike= 125 kgs

Weight of 2 persons = 75*2 =150 kgsRear suspension weight 65%For Single shock absorber Weight = W/2 = 1617NMaximum stress induced in the spring

Smax =

Where C = Spring Index = D/d

And Spring Rate k =

For Honda Spring S max = 151.37 N/mmFor Yamaha Spring S max= 169.94 N/mmFor Case-1 Spring S max = 173.82N/mmFor Case-2 Spring S max = 148.03N/mm

Here both the springs has varying pitches for varyingheights.

II. MODELING Solid works Organization was established in December

1993 by Massachusetts Foundation of Engineeringgraduate Jon Hirschtick. Jon Hirschtick selected a group ofspecialists to fabricate an organization that created 3dScoundrel programming that was not difficult to utilize.The Solid works application is a mechanical configurationrobotization programming bundle used to make parts,gatherings, and drawings which exploit the recognizableMicrosoft Windows graphical client interface. Solid Worksis a simple to learn configuration and dissection instrument,(COSMOS Xpress, COSMOS Works, Universe Flo Works,and COSMOS Motion) which makes it workable forarchitects to rapidly draw 2d and 3d ideas, make 3dsections and get-togethers, and subtle element 2d drawings.In Solid Works part, gathering, and drawing reports are allrelated. Here the spring has been demonstrated with presentHONDA CB UNICORN measurements on Solid Works-11. Based on the stresses developed in the above springs,new springs have been modified with new dimensions toreduce the stresses.

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Fig. 1: Honda Spring (3D Model)

Fig. 2: Yamaha (3D Model)

Case: 1Here the dimensions of existing springs have been

considered for modifications. By changing the dimensionsof above springs the new spring has been modified as

below.

Fig. 3: Case-1

Case: 2

And here the Honda dimensions are modified forreducing the stresses. For both the cases 3D model isdeveloped using Solid works and then analysis is doneusing ANSYS.

Fig. 4: Case-2

III. I NTRODUCTION TO FEAFinite Element Analysis (FEA) was initially created in

1943 by R. Courant, who used the Ritz technique fornumerical investigation and minimization particle ofvariational math to get rough answers for vibrationframeworks. In no time from that point, a paper distributedin 1956 by M. J. Turner, R. W. Clough, H. C. Martin, andL. J. Topp made a more extensive meaning of numericaldissection. The paper fixated on the "firmness andavoidance of complex structures". By the early 70's, FEAwas constrained to extravagant centralized serverworkstations for the most part claimed by theaeromechanics, auto, barrier, and atomic businesses. Sincethe quick decrease in the expense of machines and theuncommon build in registering force, FEA has been createdto an amazing exactness. Present day supercomputers are

presently equipped to create correct results for numeroustypes of parameters. FEA comprises of a machine model ofa material or outline that is focused on and examined for

particular results. It is utilized within new item outline, andexisting item refinement. An organization can confirm a

proposed outline will have the capacity to perform thecustomer's specificity particles before assembling ordevelopment. Altering a current product or structure is usedto qualify the product or structure for anotheradministration condition.

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If there should be an occurrence of structural

disappointment, FEA may be utilized to assist focus theconfiguration adjustments to meet the new condition. Thereare by and large two sorts of examination that are utilizedas a part of industry: 2-D demonstrating, and 3-Ddisplaying. While 2-D demonstrating savesstraightforwardness and permits the investigation to be runon a moderately ordinary workstation, it has a tendency toyield less correct results. 3-D demonstrating,notwithstanding, delivers more correct results whilerelinquishing the capability to run on everything except thespeediest machines successfully. Inside each of thesedisplaying plans, the developer can embed variouscalculations (capacities) which may make the framework

act directly or non-straightly. Straight frameworks are farless intricate and for the most part don't consider plasticdistortion. Non-straight frameworks do represent plasticdeformity, and a lot of people likewise are equipped fortesting a material the distance to crack.

FEA utilizes a complex arrangement of focuses calledhubs which make a framework called a cross section. Thiscross section is modified to hold the material and structural

properties which characterize how the structure willrespond to certain stacking conditions. Hubs are allocatedat a certain thickness all through the material relying uponthe foreseen anxiety levels of a specific range. Areas whichwill get a lot of anxiety generally have a higher hubthickness than those which encounter practically zeroanxiety. Purposes of investment may comprise of: break

purpose of beforehand tried material, filets, corners,complex subtle element, and high stretch ranges.The meshacts like a spider web in that from each node, there extendsa mesh element to each of the adjacent nodes. This web ofvectors is what carries the material properties to the object,creating many elements.

Many FEA programs also are equipped with thecapability to use multiple materials within the structuresuch as:

Isotropic, identical throughoutOrthotropic, identical at 90 degrees

General anisotropic, different throughoutBoth springs have been meshed in the hypermesh14.0 by

using the tetra mesh tool. The meshed models are shown below.

Fig. 5: Meshed model of Honda

Fig. 6: Meshed model of Yamaha

Fig. 7: Meshed model for Case-1

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Fig. 8: Meshed model for Case-2

IV. R ESULTS A ND D ISCUSSION ANSYS is an universally useful limited component

demonstrating bundle for numerically unraveling a widemixed bag of mechanical issues. These issues incorporatestatic/dynamic, structural investigation (both linear andnonlinear), high temperature exchange, and liquid issues,and additionally acoustic and electromagnetic issues.Generally, a finite-element solution may be broken into theaccompanying three stages.(1) Preprocessing: defining the problem,(2) Solution: assigning loads, constraints, and solving(3) Post processing: further processing and viewing of theresults

(1) In the preprocessing, the following are the major stepsinvolved(i) Defining key points / lines / areas / volumes,(ii) Defining element type and material/geometric

properties, andiii) Mesh lines / areas / volumes as required.

The measure of subtle element needed will rely on uponthe dimensionality of the analysis, i.e., 1D, 2D,axisymmetric, and 3D.

(2) Solution: allotting loads, conditions, and settlingHere, it is important to define the loads (point or

weight), conditions (translational and rotational), lastlyexplain the ensuing set of mathematical statements.

(3) Post processing: further preparing and review of the

resultsIn this stage one may wish to see

(i) arrangements of nodal relocations,(ii) component strengths and moments,(iii) diversion plots, and(iv) stress shape outlines or temperature maps

The following diagrams illustrate about the vonmisesstresses of the all springs

Fig. 9: Honda

Fig. 10: Yamaha

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Fig. 11: Case-1

Fig. 12: Case-2

V. CONCLUSION The literature review has been discussed about the

design of mechanical springs used in suspension systems isused to do it’s deign analysis which involves maximumstress analysis.

In the span of service life of spring it undergoes the

varying loads. Springs has been designed in Designsoftware SolidWorks. In this paper shear stress equation isused for calculating the maximum stress induced in thespring. Comparison has been made for theoretical resultsobtained from the shear stress equation to the FiniteElement Analysis (FEA) results. In both the cases theanalysis results gives the better results than the existingone. By these FEA results gives the better accuracy. Thereis a chance for Investigations to be made on differentalternate available suitable materials to achieve the overallweight reduction of the automobile without affecting theriding comfort of the two-wheeler suspension.

REFERENCES[1] R.S. Khurmi & J.K Gupta (2003), “A textbook of machine design”,

S. Chand & company.[2] Kommalapati. RameshBabu, 2. Tippa Bhimasankara Rao. “ Design

Evaluation of a Two Wheeler Suspension System for Variable LoadConditions” International Journal of Computational EngineeringResearch Vol. 03 Issue 4 April, 2013.

[3] S. Segla1 S. Reich2. “ Optimization and comparison of passive,active, and semi- active vehicle suspension systems” 12th IFToMMWorld Congress, Besançon (France), June18-21, 2007.

[4] Pinjarla.Poornamohan 1, Lakshmana Kishore.T 2. “Design andAnalysis of a Shock absorber” ISSN: 2319 - 1163 Volume: 1 Issue:4 578 – 592.

[5] First edition of “ Practical Finite Element Analysis” by Nitin SGokhale, Sanjay S Deshpande, Sanjeev V Bedekar, Anand N Thite.

[6] www.yamaha-motor.gr[7] P.S.Valsange “Design Of Helical Coil Compression Spring” A

Review” (IJERA) Vol. 2, Issue 6, November - December 2012, pp.513-522

[8] Niranjan Singh “General review of mechanical springs used inAutomobiles suspension system” Singh, international journal ofadvanced engineering research and studies, E-ISSN2249 – 8974, Int.J. Adv. Engg. Res. Studies/iii/i/oct.-dec.,2013/115-122 Reviewarticle

[9] Adam G. Rasbach, Orion, MI (US). “United States PatentApplication Publication” Pub. N0.: US 2013/0127101 A1 Rasbach(43) Pub. Date: May 23, 2013.

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