A Project Stage-I Report on

Design and Performance

Analysis of Modern Material
used in Shock Absorber.
By

Shivraj Madhavrao Bokare

Shivam Santosh Kamthekar
Pavan Manikrao Kadam
Shubham Tanaji kadam

Guided By
Mr. B.A. Phugate
––

Department of Mechanical Engineering

G. H.Raisoni Institute of Engineering And Technology
Wagholi
 G. H.Raisoni Institute of Engineering And Technology
Wagholi, Pune.

CERTIFICATE

This is to certify that Mr. Shivraj Bokare, Mr. Shivam

Kamthekar, Mr. Pavan Kadam , Mr. Shubham kadam has
successfully completed the Project stage-1 entitled “Design
and performance analysis of modern material used in
shock absorbers” under my supervision, in the partial
fulfillment of Bachelor of Engineering – Mechanical
Engineering of University of Pune.

Date :28 Dec 2021

Place : GHRIET pune

Mr. B A Phugate
Guide

Dr. A. M. Thakare Dr. R. D. Kharadkar

Head of the Dept. Principal

 AKCKNOWLEDGEMENT

I would like to express my special thanks of gratitude to my guide

"Mr. B. A. Phugate" for their able guidance and
support in completing my Project. “Design and material analysis of
shock absorber.”
I would also like to extend my gratitude to the Principal Sir
“ Dr. R. D. Kharadkar” and head of the department "Dr. A. M. Thakare
for providing me with all the facility that was required.

Date: 28/12/2021 Name of students

Shivraj Madhavrao Bokare
Shivam Santosh Kamthekar
Pavan Manikrao Kadam
Shubham Tanaji Kadam

Faculty of Science and Technology-Mechanical Engineering- GHRIET, Pune. 3

Project by- Shivam kamthekar, Shivraj Bokare, Pavan Kadam, Shubham Kadam
 INDEX
Certificate …3
Acknowledgement ...4
Introduction …5
Literature Review …7
Work plan …12
Material Selection …13
Future Scope …15
2D Design And 3D Model …16
Design …17
Drafting Sheet …18
Reference …19

Faculty of Science and Technology-Mechanical Engineering- GHRIET, Pune. 3

Project by- Shivam kamthekar, Shivraj Bokare, Pavan Kadam, Shubham Kadam
OBJECTIVES:
To perform theoretical analysis of shock absorber.
To reduce amplitude of disturbance.
To study the heat, transfer from damper fluid to Shock Absorber body to give
comfort and smooth ride.

INTRODUCTION ABOUT PROJECT:

A shock absorber is a mechanical device designed to smooth out or damp shock impulse, and
dissipate energy. The shock absorbers duty is to absorb or dissipate energy. In a vehicle, it
reduces the effect of travelling over rough ground, leading to improved quality, and increase
in comfort due to substantially reduced amplitude of disturbances. When a vehicle is
travelling on a level road and the wheels strike a bump, the spring is compressed quickly.
This bouncing process is repeated over and over, a little less each time, until the up
and down movement finally stops. If bouncing is allowed to go uncontrolled, it will not only
cause an uncomfortable ride but will make handling of the vehicle very difficult. The design
and selection of material of spring in suspension system.
To analyse the Shock Absorber coil by designing on CATIA then import into
ANSYS so we could analyse by changing its materials based on selection. So, that cost
required to analyse by practically will be minimized.
In a vehicle, it reduces the effect of traveling over rough ground, leading to improved
ride quality, and increase comfort due to substantially reduced amplitude of disturbances.
Without shock absorbers, the vehicle would have a bouncing ride, as energy is stored in the
spring and then released to the vehicle, possibly exceeding the allowed range of suspension
movement. Control of excessive suspension movement without shock absorption requires
stiffer springs, which would in turn give a harsh ride. Shock absorbers allow the use of soft
springs while controlling the rate of suspension movement in response to bumps. Damp the
motion of the upspring weight up and down on the springiness of the tire. Since the tire is not
as soft as the springs, effective wheel bounce damping may require stiffer shocks than would
be ideal for the vehicle motion alone. Spring based shock absorbers commonly use coil
springs though torsion bars can be used in tensional shocks as well. Ideal springs alone,
however, are not shock absorbers as springsonly store and do not absorb energy. Vehicles
typically employ springs and torsion bars as well as hydraulic shock absorbers. In this
combination, shock absorber is reserved specifically for the hydraulic piston that absorbs and
dissipates vibration.

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Faculty of Science and Technology-Mechanical Engineering- GHRIET, Pune.
Project by- Shivam kamthekar, Shivraj Bokare, Pavan Kadam, Shubham Kadam
 Most of shock absorber contains the air gap inside the shock absorber between
internal cylinder and outer body, Air gap has lower heat transfer rate, and so Problem of
overheating will be effect of damping fluid characteristics and decrease shock absorber
performance, to improve heat transfer air gap is filled by fluid substance like turpentine,
methanol and Water with coolant and collect Required data of improved Heat Transfer into
Shock Absorber , Finally turpentine and methanol increase heat transfer but water with
coolant give maximum heat transfer rate. With increase heat transfer rate from inside
absorber to surroundings problem of overheating of damper fluid should be decrease and
shock absorber performance increase.

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Faculty of Science and Technology-Mechanical Engineering- GHRIET, Pune.
Project by- Shivam kamthekar, Shivraj Bokare, Pavan Kadam, Shubham Kadam
 LITERATURE REVIEW:

Sr. No. Year Author Description

1. 1993 Kim An analysis of a twin tube damper with focus on

implementation into a vehicle suspension system. Kim's
model included chamber compliance and fluid
compressibility which yielded a differential equation for
the chamber pressures that was solved using the Runga
Kutta Method. Incorporating damping data into a quarter
car model, the frequency response of the sprung mass and
tire deflection were calculated numerically.

Designed a physical and mathematical model for a twin-

2. 2012 Ferdek et tube hydraulic shock absorber, using oil as the working
al medium. To analyse the model, methods of numerical
integration were incorporated. The basic characteristics
of the damping force were also obtained. The velocity
sensitive and nominally symmetric hydraulic dampers
were considered.

3. Suggested a new mathematical model of displacement

2005 Lee sensitive shock absorber to predict the dynamic
characteristics of automotive shock absorber. The
performance of shock absorber is directly related to the
vehicle behaviours and performance, both for handling
and ride comfort.

4. 2013 Focused on to develop new correlated methodologies

that will allow engineers to design components of shock
Martande absorbers by using FEM based tools. The different stress
and deflection values in shock absorber components
have been obtained using FEA tools and compared with
analytical solutions. Percentage error is calculated and it
s found that percentage error is less than 15%.

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Faculty of Science and Technology-Mechanical Engineering- GHRIET, Pune.
Project by- Shivam kamthekar, Shivraj Bokare, Pavan Kadam, Shubham Kadam
 Designed shock absorber for 150 cc bikeusing CATIA.The
5. 2012 Poornamohan model was also changed by changing the thickness of the
spring. They have performed the structural analysis and
modal analysis on the shock absorber by varying material
for spring, to steel and Beryllium Copper.

The model of a complete system, consisting of a

variable damping shock absorber and a servo-
hydraulictester, used to evaluate the vibration levels
6. 2010 Ferdek et al produced bya shock absorber.
And gives the configurations of a typical valve system
including three basic regimes of operation, which
correspond to the amount of oil flowing through a valve
cavity. The aim of this work was to propose a finite
element fluid flow model, which can be used in order to
reduce the velocity of fluid flow through a cavity of a
shock absorber valve..
Studied the spring steel and carbon fibre for the
7. 2014 R.Kannan analysis of helical spring. He designed and created a
3D model using SOLID works. He did structural
analysis for both materials. The analysis was done by
various factors such as loads, weight for a single person
and double person. The modelling was done in SOLID
works and analysis was done in ANSYS. He concluded
that “Spring Steel is better Than a Carbon Fibre”. The
various parameters like stress, deformation, strain were
having better results for spring steel than carbon fibre.
The load of 1753N was applied to observe the
deformation and the coil used had outer diameter of
70mm.The weight of a person and two persons are
considered to demonstrate the parameters. The overall
weight of the system became 178.75 kg [1753N].

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Faculty of Science and Technology-Mechanical Engineering- GHRIET, Pune.
Project by- Shivam kamthekar, Shivraj Bokare, Pavan Kadam, Shubham Kadam
 8. The shock absorbers for automobile of capacity 150cc
2016 Kartik A. S. by varying material for spring using NX
at el UNIGRAPHICS 10. They then compare the models by
analysing structural and modal analysis of the models of
Structural Steel, Titanium alloy, Copper alloy and
Aluminium alloy material on ANSYS 14.5. They
considered the loads, bike weight with single person and
2 persons for the analysis..

9. Focused on to develop new correlated methodologies

that will allow engineers to design components of
Martande shock absorbers by using FEM based tools. The
2013
different stress and deflection values in shock absorber
components have been obtained using FEA tools and
compared with analytical solutions. Percentage error is
calculated and it is found that percentage error is less
than 15%.

10. Presented the model of a complete system, consisting

Piotr Czop & of a variable damping shock absorber and a servo-
2011
Damian hydraulic tester, used to evaluate the vibration levels
Slawiki produced by a shock absorber.

11. Designed different models of shock absorbers by

varying material for spring using Pro/E Creo and
M.Shobha analysed using ANSYS. She then compared the models
2015
by analysing structural and modal analysis of the
models of Spring Steel, Phosphor Bronze and
Beryllium Copper material on ANSYS. Aim of the
study was to find the best material for the spring in
shock absorber.

12. 2015 Rahul Tekade Designed a shock absorber to improve the comfort and
and safety of the passengers of the vehicle and also sustain
ChinmayPatil the vibrations. They performed the structural and modal

analysis of the shock absorber of the vehicle. They

concluded that for the spring ASTM A228 (high carbon
spring wire) will provide optimum results.

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Faculty of Science and Technology-Mechanical Engineering- GHRIET, Pune.
Project by- Shivam kamthekar, Shivraj Bokare, Pavan Kadam, Shubham Kadam
 13. 2014 Sourabh G. Demonstration of composite material like a combination
Harale and M. of conventional steel and a metal matrix composite of E-
Elango Glass fibre/Epoxy reinforced material in helical coil
spring suspension. The results showed that there was
decrease in the weight and increase in stiffness of the
system but it also pointed out limitations like cost and
manufacturing of E-
Glass fibre, low stiffness of single
composite spring.
14. 2014 P. Karunakar Performed the comparative design analysis of the two
et al wheeler shock absorber and designed the models of
shock absorbers by varying material for spring using
Creo. Also, they compared the models by analysing
structural and modal analysis of the models of Structural
Steel (ATM-A316), Inconel X750 and Nickel 2000
material on ANSYS. They conclude that Inconel X750
is best suited material for the spring of shock absorb.

15. 2012 Pinjarla. Designed different models of shock absorbers by

Poormoan varying material for spring. They then compare the
and models by analysing structural and modal analysis of
Lakshmana the models of Spring Steel and Beryllium Copper
Kishore T. material. They used the Reengineer for the modelling
and ANSYS for the analysis of the shock absorber

16. 2013 SudarshanMa Developed new correlated methodologies which will

rtande et al enable engineers in designing components of Shock
Absorbers by using FEM based tools like ANSYS.
They performed the experiment on a bike with 194kg
weight, one person and then with two persons. They
compared the FEA results with the analytical solutions
and found out the errors to be 15%.
1 2020 Shock absorber is a mechanical device designed to
smooth out or damp shock impulse, and dissipate kinetic
N.AnkithaE
energy. In this work, suspension system is designed and
mail author
a 3D model is created using CATIA V5R21. Structural
M. R. S.
analysis is done on the shock absorber by varying
Rupa Sri
different spring materials. Spring materials are spring
steel, phosphorus bronze, beryllium copper, and titanium
alloy. To validate the strength of the model, the structural
analysis on the helical spring is done. The analysis is

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Faculty of Science and Technology-Mechanical Engineering- GHRIET, Pune.
Project by- Shivam kamthekar, Shivraj Bokare, Pavan Kadam, Shubham Kadam
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Faculty of Science and Technology-Mechanical Engineering- GHRIET, Pune.
Project by- Shivam kamthekar, Shivraj Bokare, Pavan Kadam, Shubham Kadam
 done by considering loads, bike weight, and single,
double riding. Finally, comparison is done for different
materials to verify which material suits for spring in
shock absorber.

18. 2010 Prince Jerome Designed and performed analysis of Shock Absorber
Christopher J. performance by varying diameter of the coil spring. By
and considering bike mass, loads, and number of persons
Pavendhan R seated on a bike, comparison is done to verify best
dimension of spring in the shock absorber. They used
ProE and ANSYS for the modelling and analysis
respectively.

19 2010 Demonstrated the feasibility of composite coil spring like

Budan, D. glass fibre, carbon fibre and their mixture over the
Abdul, T. S. conventional metal coil spring. The experimental
Manjunathan results show that spring rate of
carbon fibre spring is much more than the other
aterials and its weight is also lower as compared
to the other composite materials tested. Results
revealed that the spring rate of the

carbon fibre spring is 34% more than the glass fibre

spring and 45% more than the glass fibre/carbon fibre
spring. The weight of the carbon fibre spring is 18%
less than the glassier spring, 15% less than the Glass
fibre/carbon fibre spring and 80% less than the steel
spring.

20. 2012 Saurabh Demonstrated the feasibility of composite material for

Singh helical coil spring suspension system design. The
author has replaced conventional steel with a mixture
of steel and Glass Fibre/Epoxy which results in
increased stiffness of the spring. The reason of
implementing combination of steel and composite
material was the low stiffness of single composite
spring, which limits
its application to light weight vehicle only.

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Faculty of Science and Technology-Mechanical Engineering- GHRIET, Pune.
Project by- Shivam kamthekar, Shivraj Bokare, Pavan Kadam, Shubham Kadam
 WORK PLANE

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Faculty of Science and Technology-Mechanical Engineering- GHRIET, Pune.
Project by- Shivam kamthekar, Shivraj Bokare, Pavan Kadam, Shubham Kadam
 Material Selection:
 Materials such as acryl base resins and silicon base resins with low elasticity
are conventionally used as shock absorbing materials. These resin materials
have a three dimensional cross-linking network structure with covalent bonds.

 In contrast, products developed by reference to biological materials have

the feature of having a three-dimensional cross-linking network structure
that uses low energy bonds.

Based on above case we select the following materials:

1) Spring Steel:
1.1) Spring steels are generally low-alloy manganese, medium-carbon steel or
high-carbon steel with a very high yield strength.

1.2) This allows objects made of spring steel to return to their original shape
despitesignificant deflection or twisting.

2) Beryllium Copper:

2.1) The copper is high strength with non-magnetic and n-sparking qualities.

2.2) It has excellent metalworking, forming and machining properties.

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Faculty of Science and Technology-Mechanical Engineering- GHRIET, Pune.
Project by- Shivam kamthekar, Shivraj Bokare, Pavan Kadam, Shubham Kadam
 3) Phosphor Bronze:

3.1) Phosphor bronze is used for suspension in moving coil

galvanometer because it has low torsional constant.

3.2) Its restoring torque per unit twist is small. Due to it, the galvanometer
is very sensitive.

3.3) It is rust resisting. Hence it remains unaffected by the weather conditions

of air in which it is suspended.

3.4) Also, it is non-magnetic and does not oxidise easily.

4) Titanium:

4.1) Titanium follow logically from high strength, low density and low modulus.

4.2) It have good flexibility.

4.3) It have excellent resistance to corrosion and oxidation.

Steps Involved in Design Work:

1. Gathering all relative data for the design of Shock Absorber.

2. Generation of model using CATIAV5.

3. Importing the generated model to ANSYS for analysis work

4. Static analysis is carried out on the Shock Absorber to evaluate the performance.

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Faculty of Science and Technology-Mechanical Engineering- GHRIET, Pune.
Project by- Shivam kamthekar, Shivraj Bokare, Pavan Kadam, Shubham Kadam
 Future Scope:

1. By using copper alloy in shock absorber to reduce weight and increase the
comfort level by measuring force transmission at both ends of helical
compression spring.

2. To compare the material property of suspension spring

system under low and high weight and time variation.

3. Improvement in shock absorber fluid, and additive or substance for increase heat
transfer should be obtain

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Faculty of Science and Technology-Mechanical Engineering- GHRIET, Pune.
Project by- Shivam kamthekar, Shivraj Bokare, Pavan Kadam, Shubham Kadam
 2D Diagram & 3D model:

Fig.2D Diagram

fig. 3D Diagram

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Faculty of Science and Technology-Mechanical Engineering- GHRIET, Pune.
Project by- Shivam kamthekar, Shivraj Bokare, Pavan Kadam, Shubham Kadam
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Faculty of Science and Technology-Mechanical Engineering- GHRIET, Pune.
Project by- Shivam kamthekar, Shivraj Bokare, Pavan Kadam, Shubham Kadam
 Design:

Shock Absorber model in CATIA V5

Drafting Sheet
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Faculty of Science and Technology-Mechanical Engineering- GHRIET, Pune.
Project by- Shivam kamthekar, Shivraj Bokare, Pavan Kadam, Shubham Kadam
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Faculty of Science and Technology-Mechanical Engineering- GHRIET, Pune.
Project by- Shivam kamthekar, Shivraj Bokare, Pavan Kadam, Shubham Kadam
 REFERENCES:

1. Karthik A. S. et al, Design and static analysis of shock absorber–International Journal for
Innovative Research in Science & Technology, Volume 2, Issue 12, May 2016.

2. M. Shobha, Design and analysis of Mono shock absorber in two wheelers, International
Interdisciplinary Research Journal, (Bi-Monthly), ISSN 2249-9598, Volume-V, Issue-II,
Mar-Apr 2015 Issue.

3. Pinjarla. Poormohan and Lakshmana Kishore T, “Design and Analysis of a Shock

Absorber”, International Journal of Research in Engineering and Technology, ISSN:
2319- 1163, Volume: 1, Issue: 4, pp.578-592, December 2012.

4. John C. Dixon, "The Shock Absorber Handbook", 2nd Ed., John Wiley & Sons
Ltd, England, 2007.

5. Suresh Raddy,Thontaraj Urs T.S 2014 “Comparative Study of Static Structural Analysis
of a Shock Absorber for Different Material”, International Journal of Engineering
Science and Innovative Technology (IJESIT) Volume 3, Issue 6, November 20