FABRICATION AND ANALYSIS OF SUSPENSION SYSTEM

PURAN SINGH, VAIBHAV SINGH ADHIKARI, SHUBHAM CHAWLA, MANIT

AHUJA, HARSHIT AHUJA AND RITVIK PANDEY.

MECHANICAL & AUTOMATION ENGINEERING

AMITY SCHOOL OF ENGINEERING & TECHNOLOGY

ABSTRACT will be impacted. Thereafter, the model

To carry out the objective of redesign
hubs of a car, first step is modelling the
piece with the damping system; add in it
the movement restrictions and the most
similar loads or forces which the piece
will be impacted. Thereafter, the model
is analysed.
If necessary, you can change the size of
the model, but this has to fit into the
design of the rest of the vehicle and
support the loads. Finally, the final
model is analysed. Data obtained in tests
is analyzed. If necessary, you can change
the size of the model, but this has to fit
into the design of the rest of the vehicle
and support the loads. Finally, the final
model is analyzed. Data obtained in tests
for the designs and redesigns of the
vehicle were used. With the information,
the piece is simulated in critical
situations, the behaviour is observed and
the features are improved (agility,
flexibility, cost, etc.).
PROJECT DESCRIPTION
The objective of the project is to
fabricate and analysis of a suspension
system for an ATV. With this objective
the project is divided in 2 modules as:

for the designs and redesigns of the  Fabrication

vehicle were used. With the information,  Analysis

the piece is simulated in critical FABRICATION

situations, the behaviour is observed and
the features are improved (agility,
flexibility, cost, etc.).
INTRODUCTION
To carry out the objective of redesign
hubs of a car, first step is modelling the
piece with the damping system; add in it
the movement restrictions and the most
similar loads or forces which the piece
The first step in the process as we design
the required part and various analysis is
done on the designed part to ensure that
the part will meet the strength and
durability.
There are several considerations when
designing a hub. Loads and forces need
to be considered. Vertical and horizontal
forces greater than those due to 5 times
the acceleration of gravity, that is, about
50 meters per second per second, are
sometimes considered desirable.
Non-driven wheel ANALYSIS RESULTS
The main forces on a non-driven wheel
are braking and turning forces. 1.STATIC HUB RESULTS

Driven wheel Name Min Max

The forces on a driven wheel include Stress1 14.1864 1.31949e+009
forward and reverse propulsion as well N/m^2 N/m^2
as the braking and turning forces. Node: Node: 11255
15639
Displaceme 0 mm 1.40816 mm
 Finite Element Method
nt1 Node: 688 Node: 1699
 Mesh
Strain1 2.01621e- 0.0131508
010 Element: 4680
Suspension system design tips:
Element:
7635
 General shape. Factor of 0.116183 2.30693e+009
 Keep it small. Safety1 Node: Node: 15911
 Material specification. 11216
 Surface finish & appearance.
 Coarse versus fine threads for
fasteners.
 Design parts to take advantage of
nominal raw material size. 2. ROTATING HUB RESULTS
Name Min Max
SELECTION OF MATERIAL Factor of 0.239757 557.157
Safety1 Node: 33 Node: 64
After completion of all the material Strain1 1.13443e- 0.0140147
survery in the market and on the internet 005 Element:
facility. We have decided to go with the Element: 2203
following material: 1577
Displacem 0 mm 0.154321
For Static Hub, ent1 Node: 1 mm
MATERIAL NAME: Gray Cast Iron Node: 7038
Stress1 493578 1.147e+009
For Rotating Hub, N/m^2 N/m^2
MATERIAL NAME: 6061-T6 Node: 64 Node: 33

For Trailing Arm,

MATERIAL ANEM: Gray Cast Iron
 3.TRAILING ARM RESULTS executed. We have developed a system,
which would be the precursor for the
Name Min Max future developments.
Stress1 0.411713 3.26361e+007 The results of the project are as: -
N/m^2 N/m^2
Node: 62 Node: 12496 1. DESIGNING & FABRICATION
Displacem 0 mm 0.236897 mm  Fabrication of the mechanical
ent1 Node: Node: 850 structure is accomplished.
304  Fabrication of the static hub and the
Strain1 4.07492e- 0.000364632 rotating hub which is mounted on the
012 Element: 7038 wheel is done.
Element:  Fabrication of trailing arm,
3522 supporting plates, bushes and
Factor of 5.96891 6.2403e+010 mounting of the entire assembly on
Safety1 Node: Node: 10375 the worktable is done satisfactorily.
11461  Coupled with the axles, the required
desired motion of the suspension
system is achieved.

2. DEVELOPING DESIGN CODE

FABRICATION AND ASSEMBLY A design has been developed in
SOLIDWORKS 2016 that gives the
This phase deals with the fabrication and e design and simulation..
assembly of the individual components.
3. EXPERIMENTAL TESTING
The Various manufacturing processes
Experiments were carried out on the
like turning operation, thread cutting,
ATV vehicle satisfactorily by using
milling operation and welding operations
an transmission system being
have been performed to fabricate
assembled to the suspension system
in the verhicle.

PROJECT APPLICATIONS
FUTURE SCOPE
The designing of suspension system can
The Suspension system fabricated and
help in the movement of the vehicles as
fanalysed by us is an elementary system.
the components will help in vehicular
There is tremendous scope of improving
designs. The driverability also increases
this system and incorporating additional
at a very much enhanced rate as it may
features, which will further its scope and
be a calculus of sytems.. The project can
facilitate its incorporation into a real
be used to perform various such works
time automation machine, some of the
in the industries.
improvements possible are:
RESULTS ACHIEVED

The concept of developing an

suspension system of an ATV has been
  Much more swifter vehicles
as the components will help
in vehicular designs.
 Much more tedious but
helpful parts w.r.t the
driverability.
 Much more enhanced
versions which help in easier
diagnostics.

REFERENCES

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Fatigue and Fracture, 1996.
ISBN 978-0-87170-385-9 C.C.
Osgood, Fatigue Design, 2nd Ed.
1982. ISBN 978-0-47165-711-8
[2] R.C. Juvinall, Engineering
Considerations of Stress, Strain,
and Strength, 1967. ISBN 978-0-
07033-180-8
[3] H.O Fuchs and R. I. Stephens,
Metal Fatigue in Engineering,
1980. ISBN 978-047151-059-8
[4] Howard E. Boyer, Atlas of
Fatigue Curves, 1986. ISBN 978-
0-87170-214-2
[5] J.A. Ballantine, J.J. Comer, and
J.L. Handrock, Fundamentals of
Metal Fatigue Analysis, 1990.
ISBN 0-13-340191-X
[6] N.E. Dowling, Mechanical
Behaviour of Materials, 1993.
ISBN 978-0-273-76455-7