Design and Analysis of a Shock Absorber Using ANSYS

Yuli Setiyorini1.b*), Sungging Pintowantoro1.c), Fahny Ardian1.c), Anni Rahmat1.d)

1Material
Engineering Department, Sepuluh Nopember Institute of Technology, Surabaya,
East Java, Indonesia 60111
2Chemical Engineering Department, Semen Indonesia International University, Gresik,

East Java, Indonesia 61122

a)yuli_setyorini@mat-eng.its.ac.id
b) sungging@mat-eng.its.ac.id
c) fahny1923@gmail.com
d) ar_298@yahoo.com

Keywords: Finite Element Analysis, Design, Shock Absorber, Safety Factor, Modal
Abstract. The shock absorber is a component that connects a vehicle to its wheels and affected to the
vehicle’s road handling and braking. The shock absorber has to smooth shock impulse and dissipate
kinetic energy. If the shock absorber cannot smooth the disturbance, will shorten the vehicle's
component life. The design of spring and materials selection in the shock absorber are very essentials.
In this paper, a shock absorber was modelled using SolidWorks 2014. The model is also varying
diameter and type of the spring. Structural analysis and modal analysis are done on the shock absorber
using ANSYS 19.1. Structural analysis is done to calculate the mechanical strength and lifetime of
the design and modal analysis is done to determine the deformation for different natural frequencies
for the number of modes. The performance of the new shock absorber designs was investigated for
ASTM A231 and AISI 9255 materials and compared to each other. Based on the static structural
analysis result, the safety factor for the fatigue life of the shock absorber design has been calculated
based on Goodman, Soderberg, and Gerber fatigue theories.

Introduction
The shock absorber is a main component of vehicle, aircraft, trains and the supports for many
industrial machines [1]. Shock absorbers have been used in buildings to reduce the probability of
various structures to earthquake damage. Shock absorb is a mechanical part designed to smooth out
or damp shock impulse and dissipate kinetic energy. Pneumatic and hydraulic shock absorbers
generally have form a cylinder with a sliding piston inside. This absorber commonly filled with a
fluid or air. This fluid-filled piston/cylinder combination is a dashpot [2]. One of design consideration,
when designing or choosing a shock absorber, is where that energy will be release. In general
dashpots, energy is converted to heat inside the viscous fluid. In hydraulic cylinders, the hydraulic
fluid will heat up, while in air cylinders, the hot air is usually exhausted to the e. In general terms,
shock absorbers help cushion cars on uneven tracks. The vehicle without shock absorber probability
have problems in handling, as energy which stored in the spring and then released to the vehicle
[3][4].
The spring of shock absorber able to operate in any conditions under a wide range of
temperatures. The spring store energy rather than dissipating it [5]. Metal spring type shock absorbers
are used then measures should be provided to limit oscillations. Metal springs are often used with
viscous dampers. There are a number of different types of metal springs including helical springs,
bevel washers(cone-springs), leaf springs, ring springs and etc. Each spring type has its own operating
characteristics [6].
In other hand, the function of shock absorbers is to connect vehicles to its wheels. A shock
absorber is coupled with a spring to convert shock waves into oscillatory motion. The shock absorbers
provide a comfortable ride and stability handling to the vehicle on the uneven track. While a vehicle
hits a bump on the track, the spring of the shock absorber to coil and uncoil. The energy of the spring
is moved to the shock absorber through the upper mount, down through the piston rod and into the
piston. The shock absorber works in extension cycle and the compression cycle. In the extension
cycle, the piston moves upwards. In the compression cycle, the piston moves down and compresses
the spring. The compression cycle controls the vehicle’s unsprung weight and extension cycle
controls the sprung weight of the vehicle [7][8][9].
Finite Element Analysis (FEA) is a computer-based numerical technique for evaluating the
phenomena and behavior of engineering structures. It can be used to determine deformation, stress,
strain, contact pressure, thermal distribution of engineering design. It can be used to evaluated small
or large-scale deflection under loading or applied forces. The method is also distinguished from finite
differential equations, for which although the steps into which space is divided are finite in size, there
is little freedom in the shapes that the discreet steps can take. Finite element analysis is a way to deal
with structures that are more complex than can be dealt with analytically using partial differential
equations. FEA deals with complex boundaries better than finite difference equations and gives
answers to structural problems [10][11].
Bhasha et al. has created a 3D model of shock absorber by using CATIA V5 R21 and changed
the size of spring [12]. A shock absorber minimized the effect of shocks while travelling on uneven
tracka and increases the ride comfort and quality by minimizing the amplitude of shock. Static
structural and modal analysis is performed on shock absorber by considering different materials for
spring by using ANSYS. Structural analysis was performed to validate the strength of the shock
absorber. To evaluate the displacements for different frequencies, modal analysis was performed.
Sudarshan et al. has created a new methodology which allows designing the partr of a shock
absorber by using finite element analysis [13]. In production of shock absorbers, it is difficult to know
the accuracy and precision of shock absorber which doesn’t fail. The shock absorber is generated by
using CAD software and analysed in ANSYS workbench by considering the weight of vehicle. In the
results, deflection and stress induced in the shock absorber are studied.

Methodology
Shape and size of the shock absorbers component have significant influence on the
performance of shock absorbers a during travelling period. The design of shock absorber must
appropriate to the vehicle. In this research a series of shock absorber design with different model and
diameter of spring shown in Fig. 1 and Table 1. Spring with different model and diameter generally
have different stress concentration and stress distribution and perhaps to increase lifetime and safety
factor of the shock absorber. Spring with large diameter provide maximal stress distribution.
However, it increased the weight of shock abosrber and increase the energy consumption of vehicle.
In the other hand, spring with minimum diameter will decrease the weight of shock absorber and
increase the possibility of failure caused by stress concentration and poor stress distribution.
Therefore, this research needs to be done in order to obtain an optimal shock absorber design in terms
of weight, comfort during tarveling and good mechanical properties. In this research, 6 different shock
absorber design with varying model and diameter of spring are generated to achieve best shock
absorber design [13]
 The important component of a shock absorber are upper mount, piston rod, cylinder and lower
mount. All the different compnent of the shock absorber are cretaed separately in SolidWorks 2014
software and all the individual parts of the shock absorber are assembled in the SolidWorks 2014. On
the lower mount of the shock absorber, a fixed support is assigned to withstand the forces acting on
the shock absorber as shown in Fig. 2 Whenever a certain external load is applied on the upper mount
of a shock absorber, the shock absorber cylinder moves down and compresses the spring. For applying
the load on the shock absorber, the weight of the vehicle with two passengers is calculated.[14][15]

Fig. 1 Components of Shock Absorber

Table 1. Research Parameters

Materials Spring Model Diameter of Spring (mm)

6
Pitch 8
10
ASTM A231
6
Revolution 8
10
6
Pitch 8
10
AISI 9255
6
Revolution 8
10
Finite Element Analysis
In the present study an attempt has been made to consider safety factor and stress distribution
to determine the useful life of the shock absorber. First a finite element model of the shock absorber
was created in SolidWorks 2014. The developed model was imported in ANYS 19.1 using parasolid
extension. Static structural and modal analysis of shock absorber carried out to evaluated about the
safety factor and appropriatennes of the shock absorber model. Static analysis was performed
applying average weight of vehicle and two passanger (7500 N). A CAD model of shock absorber
was created in SolidWorks 2014 as per dimension in Fig. 1 and saved in Parasolid format, which was
then imprted in ANSYS 19.1 for further simulation [11][16]. The shock absorber were defined with
linear elastic isotropic material. Table 2 shown ASTM A231 and AISI 9255 properties were assigned
to the spring of shock absorber and ASTM 40 were given to the upper and bottom component.
Standard surface contact was defined between bottom and upper component. Coefficient of friction
equal to 0.1 was assumed as the component is generally well lubricated by fluid. The simulation of
the shock absorber which must be taken into account not to cause failure of the shock absorber. To
evaluating how static structural and modal analysis result differ from each other design of shock
absorber, with varying the materials, model and diameter of the spring. Finite element analysis of the
shock absorber were carried out using ANSYS 19.1 on a P4 2.0 GHz Intel processor PC [17].

Fig. 2 Spring Component of Shock Absorber

Table 2. Materials Properties
Possion Yield Strength UTS Density
Materials Young Modulus (GPa) (MPa) (gr/cm3)
Ratio (MPa)
ASTM 40 180 0.29 200 310 7.5
ASTM A231 190 0.29 350 650 7.8
AISI 9255 190 0.28 390 680 7.7

Result and Discussion

The rules of optimization in this research are to ensure that the shock absorber design is proper
or not. The maximum equivalent stress on the shock absorber should be lower than the endurance
limit of the materials. In addition, the stress on the shock absorber design should be evenly distributed.
The von Mises yield criterion is part of a plasticity theory that applies best to ductile materials, such
as metals. Prior to yield, the material response is assumed to be elastic. The von Mises stress is used
to predict yielding of materials under any loading condition from results of simple uniaxial tensile
tests. Fig. 3-4 shows the von Mises stress on the shock absorber design made of ASTM A231 and
AISI 9255. Table 3-4 show the result of the shock absorber simulation made of ASTM A231 and
AISI 9255. The result presented in this study indicated that when a shock absorber is loaded. From
the result can concluded that in shock absorber designm made of ASTM A231 and AISI 9255 is safe
because the maximum von misses stress in below the yield point of materials. In the other hand the
shock absorber made of AISI 9255 with revolution model and 6 mm diameter is the best design for
static loading.
Tabel 3. Stress distribution of shock absorber made from ASTM A231
Maximum Von Maximum Von Total Deformation
Diameter of
Materials Spring Model Misses Stress Misses Stress (mm)
Spring (mm)
(MPa) (MPa)
6 145.66 0.031243 23.173
Pitch 8 184.27 0.0024246 22.539
AISI A231 10 236.02 0.0091344 21.338
&
6 147.68 0.01648 23.135
ASTM 40
Revolution 8 205.81 0.016447 22.476
10 246.08 0.015345 21.172

Tabel 4. Stress distribution of shock absorber made from AISI 9255

Maximum Von Maximum Von Total
Diameter of
Materials Spring Model Misses Stress Misses Stress Deformation
Spring (mm)
(MPa) (MPa) (mm)
6 145.64 0.031546 23.172
Pitch 8 185.4 0.0022909 22.534
ASTM 9255 10 237.49 0.0080 21.326
&
6 148.79 0.016236 23.134
ASTM 40
Revolution 8 207.1 0.016767 22.47
10 247.88 0.013574 21.157

Goodman, Soderberg and Gerber theories was used for determining of safety factor of shock
absorber designs. In this research, safety factor of the shock absorber is evaluated using ANSYS
Workbench. Safety factor calculations of the shock absorber are conducted for ASTM A231 and AISI
9255 materials. In the FEA, the materials are considered to be isotropic elasticity. Therefore, the
safety factor was ensured to be more than 1 that conclude the shock absorber design is safe. The
formulation of goodman, soderberg and gerber theories can be seen in Table 5.
(𝜎𝑚𝑎𝑥 +𝜎𝑚𝑖𝑛 )
𝜎𝑚 = (1)
2
(𝜎𝑚𝑎𝑥 − 𝜎𝑚𝑖𝑛 )
𝜎𝑎 = (2)
2

N = Safety Factor, Se = Endurance Limit (MPa), Su = Ultimate Tensile Strength (MPa), 𝜎𝑚 = Mean
Stress (MPa), 𝜎𝑎 = Alternating Stress (MPa)
Tabel.5 Fatigue analyses were performed according to Goodman, Soderberg and Gerber methodes.
Fatigue Theories Formulas
𝜎𝑎 𝜎𝑚 1
Goodman ( )+( ) =
𝑆𝑒 𝑆𝑢 𝑁
𝜎𝑎 𝜎𝑚 1
Soderberg ( )+( )=
𝑆𝑒 𝑆𝑦 𝑁

𝑁. 𝜎𝑎 𝑁. 𝜎𝑚 2
Gerber ( )+( ) =1
𝑆𝑒 𝑆𝑢

From Table. 6-7, we can see that all new shock absorber design has different safety factor
values according to all fatigue theories but all new shock absorber has safety factor more than 1. This
means that all shock absorber designs are good design safe under static loading is considered. Among
new shock absorber design, the design with pitch model and 6 mm diameter of spring made of AISI
9255 better than the others. Because this design has higher safety factor value in all faigue theories.
Tabel 6. Minimum Safety Factor of Shock Absorber for ASTM A231+ASTM 40 material
Diameter of
Materials Spring Model Goodman Soderberg Gerber
Spring (mm)
6 2.77002 2.187856 3.42516
Pitch 8 2.189452 1.729405 2.707223
ASTM A231 10 1.709407 1.350217 2.113661
&
ASTM 40 6 2.732024 2.157911 3.378141
Revolution 8 1.960354 1.548415 2.423965
10 1.639539 1.295021 2.027275
Tabel.7 Minimum Safety Factor of Shock Absorber for AISI 9255+ASTM 40 material
Spring Diameter of
Materials Goodman Soderberg Gerber
Model Spring (mm)
6 2.898267 2.35471 3.583741
Pitch 8 2.276542 1.849685 2.814909
AISI 9255 10 1.77723 1.443987 2.197522
&
6 2.836793 2.304829 3.507687
ASTM 40
Revolution 8 2.038059 1.655888 2.520046
10 1.70275 1.383465 2.105434

Fig. 3 Stress Distribution of shock absorber made of ASTM A231

Fig. 4 Stress Distribution of shock absorber made of AISI 9255

Modal Analysis
Modal analysis helps to determine the vibration characteristics (natural frequencies and mode
shapes) of a mechanical structure or component, showing the movement of different parts of the
structure under dynamic loading conditions, such as those due to the lateral force generated by the
electrostatic actuators. The natural frequencies and mode shapes are important parameters in the
design of a structure for dynamic loading conditions. Modal analysis of the shock absorber were
performed using ANSYS software. Fig. 5 shows the mode shape of the shock absorber at its
fundamental frequency and Table 8-9 shows the natural frequencies of the shock absorber design for
its different vibration modes. In this research, point mass about 250 kg carried out using Modal
Analysis ANSYS 19.1 Workbench. [12][13]
 Fig. 5 Modal Analysis

Table 8. Result of Modal Analysis shock absorber made of AISI 9255 (Revolution, 6 mm)
No Mode Frequency (Hertz) Total Deformation (mm)
1 1 0.57145 1.2472
2 2 0.59758 1.2451
3 3 28.396 64.778
4 4 28.529 64.365
5 5 44.158 61.121
6 6 49.251 65.704

Table 9. Result of Modal Analysis shock absorber made of ASTM A231 (Revolution 6 mm)
Total Deformation
No Mode Frequency (Hertz)
(mm)
1 1 0.57141 1.2472
2 2 0.59767 1.2451
3 3 28 63.998
4 4 28.135 63.586
5 5 43.456 60.381
6 6 48.656 64.912

From the result of Modal Analysis shown in Table 8-9 and Figure 9-10, we can see that the
design of shock absorber made of ASTM A228 and AISI 9255 were safe for mode 1 and mode 2.
Against as in modal analysis case, the shock absorber made of both material has different result. This
indicates that the shock absorber predicted to be safe against mode 1-2 modal analysis but may fail
under modal analysis for mode 3-6.
CONCLUSION
The object of this research was to ensure the appropriateness of shock absorber design based on
finite element analysis. In this research, six different new shock absorbers are designed. Static
structural and modal analysis of the shock absorber have been done using ANSYS 19.1. Based on
static structural analysis results, safety factors for fatigue life have been calculated. Fatigue
calculations have been carried out for ASTM A231 and AISI 9255 materials based on Goodman,
Soderberg, and Gerber fatigue theories. FEA in this study show that all new shock absorber designs
are safe against static loading. Based on modal analysis the shock absorber design predicted to be
safe under modal analysis mode 1-2 but may fail under modal analysis mode 3-6. The best shock
absorber design for under static loading is new shock absorber design with 6 mm diameter and
revolution model of spring made of AISI 9255 material because this design is lighter than pitch model.
ACKNOWLEDGMENTS
This research was supported by internal funding from the Sepuluh Nopember Institut of Technology
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