SUSPENTION SYSTEM

• Do you find any difference while traveling on a bicycle,

Bullockcart and on a car

2
• Which one you feel more comfort while traveling either on

Bullock cart or car?

3
Which system in an automobile contributes comfort to the
passengers ?

Suspension system

4
What is the main purpose of the suspension system?

To provide comfort to the passengers.

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• We can observe Suspension system in car

6
 Introduction
• The automobile frame and body are mounted on the front and rear axle not directly but through
some form of strings and shock absorbers.
• This is done to damp the road shocks, transmitted to the frame.
• All these forms which perform this function are collectively called as suspension system.

• The suspension system includes springs, shock absorbers and their mountings.

• The suspension system of a motor vehicle is divided in to the rear end suspension front end
suspension.

• Broadly speaking, suspension system consists of a spring and a damper.

• The energy of road shock causes the spring to oscillate.

• These oscillations are restricted to a reasonable level by the damper, which is more commonly called
as a shock absorber. ` 7
 Objectives of Suspension System

• To give comfort to the passengers against road shocks.

• To provide a smooth riding without getting tired.

• To minimize the effects of stresses due to road shocks on the mechanism of motor vehicle, and

provide a cushioning effect.

• To isolate the structure of the vehicle from shock loading and vibration due to irregularities of the

road surface with out impairing its stability.

• To provide the requisite height to body structure as well as to bear the torque and braking reactions.

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• To keep the body of the vehicle straight when one wheel rides over a big stone / patch of hole
• To prevent the road shocks from being transmitted to the vehicle frame.
• To safeguard the occupants from road shocks.
• To provide good road holding while driving, cornering and braking.
• To preserve the stability of the vehicle in pitching or rolling, while in motion.
• To maintain proper steering geometry.
• It transfers driving torque to the wheels as well as breaking force to the chassis.

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 Requirements of Suspension System

• Minimum deflection consistent with required stability

• Low initial cost

• Minimum weight

• Minimum type wear

• Low maintenance and operating costs

• Minimum wheel hop

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Suspension System

Types of Suspension system

1. Conventional type Suspension system

2. Independent type Suspension system

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Conventional Type of Suspension System

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 Conventional Suspension System
• Conventional type of suspension was universally used before introduction of
Independent suspension

• It may use either two longitudinal leaf spring, or a transverse spring, usually in
conjunction with shock absorbers

• These assemblies are mounted similarly to rear leaf spring suspensions

• In this type of suspension, the front wheel hubs rotate on anti-friction bearings
on steering spindles, which are attached to the steering knuckles

• These assemblies are mounted similarly to rear leaf spring suspensions

• In this type of suspension, the front wheel hubs rotate on anti-friction bearings
on steering spindles, which are attached to the steering knuckles 13
 Conventional Suspension System

• To permit the wheels to be turned by the steering gear, the steering spindle

and steering knuckle assemblies are hinged on the axle ends.

• The pin that forms the pivot of this hinge is usually referred to as the kingpin.

• Forked portion is integral with the steering knuckle and fits over the end of

the axle.

• In Reverse Elliot, the ends of the axle are forked to hold the steering knuckle

extension between the ends.

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 Characteristics of Conventional type of
Suspension system

• It is double enough for heavy duty use.

• Construction is simple.

• Maintenance is simple.

• When turning, there is little tilting of the body.

• There is little change in alignment due to up and down

movement of the wheels.

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Characteristics of Conventional
Suspension system

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Independent Suspension System

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Where independent suspension system is used ?

In all passenger cars

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 Introduction to Independent Suspension System

• Independent Suspension has become almost universal in case of front axle, due to simplicity of

construction

• The linkages used in the construction of this suspension comprise the basic features of the

suspension

• In Independent suspension there is no axle beam like conventional suspension system

• Suspension for each wheel is an Independent unit and is free from the effect of one another

• In almost all cars of the present day, Independent Suspension system is used as front suspension

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Characteristics of Independent Suspension System

• Good road holding characteristics of the wheels

• The unsprung weight can be kept low

• Springs only support the body, but they do not help in positioning of wheels

• Construction is rather complex

• Since there is no axle connecting left and right wheels, the floor and the engine
mounting position can be lowered

• Change in track and alignment with the up and down motions of the wheels

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Advantages of Independent Suspension
• The independent suspension provides more space for engine accommodation.

• IT also reduces the tendency of tilting the vehicle to one side when the wheel is lifted or
drop due to the road variations.

• It also reduces the tendency of this rotating wheels to turn about the king pins due to
gyroscopic action.

• Elastic strain energy stored in a coil or torsion bar spring is greater

• Un sprung weight is reduced, which reduces tyre scrub and increases tyre life

• Softer springs are used which improves riding comfort

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Types of Independent Suspension

1. Wishbone type or parallel link type

2. Mac Pherson strut type

3. Vertical guide type

4. Swinging half-axle suspension

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Independent Suspension system

Wishbone Suspension system

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Wish-borne Type Suspension System

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Wish-borne Type Suspension System

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 Wish-borne Type Suspension System
• It is the most popular Independent suspension system

• In this, damper is installed within the coil spring

• Use of coil springs in the front axle suspension of cars is now almost universal

• It consists of upper and lower wishbone arms

• Spring is placed between lower wishbone and underside of the cross member

• vehicle weight is transmitted from the body to the coil spring through which it goes to the lower

wishbone member

• Shock absorber is placed inside the coil spring and is attached to the cross member and to lower

wishbone member

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 Wishbone Suspension System
• The wish bone arms are like the chicken wish bone or letter ‘ V’ in shape, because of which the
system is so called.

• Because of V shape the wishbones not only position the wheels and transmit the vehicle load

to the springs

• But also resist acceleration, braking and cornering forces

• Also resist acceleration, braking and cornering forces

• Upper arms are shorts in length than the lower ones to keep the wheel track constant

• Also avoids tyre scrub thus minimizing by avoiding the tyre wear

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Mac Pherson strut Suspension system

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29
Mac Pherson Strut Type of Suspension

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 Mac Pherson Strut Type of Suspension
• Simpler than double wishbone type and is also lighter

• First time in India this system has been Used on Maruthi 800 cars

• This type of suspension with anti roller bar is employed in Volkswagen Jetta
and Passat cars

• Provides road safety and improve ride comfort

• Only lower wishbones are used

• A Strut containing shock absorber and spring carries also the stub axle on
which wheel is mounted

• Wishbone is hinged to the cross members and positions the wheel

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 Mac Pherson Strut Type of Suspension

• It also resists accelerating, braking and side forces

• Gives maximum room in the engine compartment therefore it is commonly

used on front wheel drive cars

• This system is simples than double wish bone type.

• It is also lighter in weight compared with double wish bone type.

• The camber angle does not vary when the wheel moves up and down.

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Vertical guide Front Suspension

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Vertical Guide Front Suspension

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 Vertical Guide Front Suspension

• In this system the kingpin is attached directly to the cross member of the frame

• It can slide up and down as shown, corresponding to the up and down motion of

the wheel

• In this type, wheel base and wheel track remains unchanged

• But this system is having disadvantage of decreased stability

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Swinging Half-axle Suspension

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 Swinging Half-axle Suspension
• In this system, wheels are mounted
rigidly on the half-axles

• They are pivoted on their ends to the

cross member at the middle of the car

• The disadvantage of this is that up

and down movement of the wheel
cause the camber angle to vary
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 Advantages of Independent Suspension over Conventional Suspension

• Elastic strain energy stored in a coil spring is greater incase of semi-elliptical leaf spring,

which means lighter springs can be used

• In this, un sprung weight is reduced, which reduces the scrub and hence increases tyre life

• In this, softer springs can be used without increasing rolling effect. Soft spring improves
riding comfort

• When anti-roll bar is used in Independent suspension, springs employed may be even
softer, as in the event of vehicle cornering

• In this engine and chassis frame will be placed relatively lower

• As the engine position moved forward, it results in more space for passengers

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• Did you observe leaf spring of a truck

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 Function of Springs
▪ Springs are placed between the road wheels and the body

▪ When the wheel comes across a bump on the road, it moves upon and
deflects the spring, thereby storing energy therein

▪ On releasing, due to the elasticity of the spring material, it rebounds thereby

expanding the stored energy

▪ In this way the spring starts vibrating

▪ But with amplitude decreases gradually on account of internal friction of the

spring material

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 Qualities of a Good spring

• Spring used for suspension system should absorb road

shocks quickly and return to its original position slowly

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Types of Suspension Springs

Suspension springs are mainly classified in to

• Steel springs
• Rubber springs
• Plastic springs
• Air spring
• Hydraulic spring

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Rubber springs are further classified into

• Compression spring
• Compression – shear spring
• Steel - reinforced spring
• Torsion spring

9A404.39 43
Steel springs are further classified in to

• Leaf spring
• Tapered leaf spring
• Coil spring
• Torsion bar

9A404.39 44
Leaf springs are further classified into

• Semi – Elliptical leaf spring

• Quarter Elliptical leaf spring
• Transverse spring

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Leaf Spring

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47
 Laminated Springs

• The first spring leaf is called Leaf springs. these are used in almost all the vehicles
particularly in Trucks
• In Trucks, leaf springs are used both in front and rear axles
• Leaf spring assembly is generally made-up of 5 to 12 spring steel leaves
• These are held together with the help of a center bolt and kept in position by spring
clips
• These spring clips are called as Rebound clips in leaf or master leaf

• The master leaf having eyes at its ends the eyes are used for mounting purpose

• The leafs are vary in length

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 Laminated Leaf Spring
• The spring is supported on the axle by means of a U - bolt
• One end of the spring is mounted on the frame with a simple pin and the
other end connection is made with a shackle

• When the vehicle comes across a projection on the road surface, the wheel
moves up, deflecting the spring

• This changes the length between the spring eyes

• If both the ends are fixed, the spring will not be able to accommodate this
change of length
• This is provided for by means of a shackle

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 Laminated Springs

• In Maruthi car only one leaf is used.

• In Van only 3 leaves are used at the rear axle which is a dead axle.

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• Did you observe coil springs in any vehicle?

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Coil Spring

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 Coil Springs
• The coil springs are used mainly with independent suspension

• The energy stored per unit volume is almost double in the case of coil springs
than the leaf springs

•Coil springs do not have noise problems

• Coil springs do not have static friction causing harshness of ride as in case of
leaf springs
•The spring takes the shear as well as bending stresses
• The coil springs, however, cannot take torque reaction and side thrust, for
which alternative arrangements have to be provided
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 Coil Springs

Coil springs

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 Coil Springs

Coil springs

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What are the differences between Leaf spring and Coil spring?

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 Leaf spring Coil spring

(1) More suitable for (1) More comfort to

commercial applications passengers and better
and rough roads road grip.

(2) Less maintenance cost (2) Maintenance free for

quite longer time

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(3) Easy wheel alignment. (3) Wheel alignment is
comparatively complex

(4) Suitable for modifications (4) Does not get disturbed

owing to overloading and until there is accident
repairs

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Torsion Bar

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 Torsion Bar

• It is made out of spring steel, solid bar or tube

• The amount of energy stored per unit weight

of material is same as that of coil springs

• It is mainly used unity Independent suspension

system

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Torsion Bar

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 Torsion Bar
• One end of the torsion bar is secured in the chassis frame as shown at figure

• Other end is coupled with the help of coupling C to the lower arm spindle

•When the wheel is lifted up or down, the torsion rod gets the twisting effect

• The elasticity of the rod is utilized to bring back the wheel to its normal position in
the same manner as a spring arrangement

•The torsion bar can located transversely or parallel to the frame

• In most of the cases, it is located parallel to frame as in ambassador car

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 Torsion Bar
• In certain cases, instead of one, two torsion rods are also used as
in German make Volkswagon shown in figure
• Upper and lower arms connected to torsion bar with suitable
adopters
• The loose ends of torsion bars are fixed to the chassis frame
•Usually torsion bar does not require much attention.
• But
once the vehicle is abused by overloading or running on rough
roads, torsion rod can break.
•Over and above this dead weight on the vehicle is reduced
considerably as the system is light in weight
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Advantages
• The system is neat, compact

• It does not require much attention

• Torsion bar is lighter in weight compared to the leaf springs

Disadvantages
• It cannot take up driving and breaking torque effectively for that we have to

make alternate arrangements.

• Absence of friction force and hence of damping which is a necessity to

control the vibrations produced due to road shocks

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German Make Volkswagon

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 Objectives

On completion of this topic you would be able to

learnt about:

Types Leaf springs

9A404.42 66
Identify the Difference Between These Springs

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 Types of Leaf Springs

Leaf springs are of the following types :

• Semi-elliptical spring

• Quarter-elliptical spring

•Three-quarter-elliptical spring

• Transverse spring

• Full-elliptical spring

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Semi-elliptical spring

Fig (1)
9A404.42 69
 Semi-elliptical Spring

• Semi-elliptical springs are usually used in all the vehicles.

• In Trucks, semi-elliptical springs are fitted in front and rear axles.

• In cars they are fitted on the rear axle only and the

• Independent suspension is fitted on the front axle.

• Semi-elliptical springs are cheaper and require less repairing.

• They increase the range of spring action and last for along time.

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 Quarter-elliptical Spring

• Quarter-elliptical springs were used in old small cars, like

Chrysler cars.

• This type of spring consists only a quarter portion of the

full-elliptical spring and fitted with the frame by bolts.

• This spring is outdated now due to decreased stabilities

9A404.42 71
Quarter-elliptical spring

Fig (2)
9A404.42 72
 Three-quarter elliptical Spring

• Three quarter elliptical spring is the combination of

semi-elliptical and quarter elliptical springs.

• This type of spring was used in old cars.

• This spring is out dated now

9A404.42 73
 Three Quarter-elliptical spring

Fig (3)

9A404.42 74
 Transverse spring

• Transverse spring is just like the semi-elliptical spring but inverted in shape.

• One end of the spring is joined with chassis frame by shackle.

• Other end is joined with the axle.

• It is also fixed with frame by bolts at the centre.

• It is joined to this frame by means of shackles

• This spring is outdated now due to decreased stabilities.

9A404.42 75
Transverse spring

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 Full-elliptical Spring

•Full-elliptical spring consists of two semi-elliptical

springs joined together oppositely.

9A404.42 77
 Full elliptical spring

Fig (5)
9A404.42 78
 Full-elliptical Spring

This type of spring was used in old cars.

They do not maintain correct axle alignment.

This spring is popularly used in tricycle.

9A404.42 79
What is stabilizer bar ?

9A404.43 80
Stabilizer Bar

Stabiliz
er
Bar
fitted
to a
vehicle

9A404.43 81
 Stabilizer Bar

• Both with rigid axle and independent suspension avehicle has tendency to roll to

one side i.e. tilt when sharp turn is negotiated

• To stop tilting of the vehicle stabilizer rods are placed

•If one wheel tilting, presses the other side wheel down thus maintaining the
vehicle in level position

• It is also called as ‘sway bar’

• It is necessarily used in all independent front end suspension

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Stabilizer Bar
• It reduces the tendency of the vehicle to roll when taking a turn

• A stabilizer is simply a bar of alloy steel units arms at each end connected to the lower wish bone arms

• It is supported in bush bearings fixed to the frame

• It is parallel to the cross member

• When both the wheels deflect up or down by the same amount, the bar simply turns in the bearing

• When only one wheel deflects, one end of the bar moves, thus twisting the bar which acts as a spring between
the two sides

• Mostly the stabilizer rods are made of Chrome

• steel which are fixed in front wheels

• In some of the vehicles these are fitted at rear axle also

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Stabilizer rod as fitted in Front
suspension

9A404.43 84
Stabilizer Rod as Fitted in Front Suspension

Fig 3

9A404.43 85
Stabilizer Bar

• Stabilizer rod as shown in the figure is fitted to the independent suspension to front axle

• Here B is stabilizer rod clamped to the chassis with the help of rubber bushes

•The ends of this stabilizer rod are linked to lower arm I with the help of link rod C

• S is the upper link

•T is the front cross member

• V and W are the lower and upper end of swivel pin

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Stabilizer rod as fitted to Rear suspension

87
Stabilizer rod as fitted to Rear Suspension

88
 Stabilizer bar

• The stabilizer rod linked to the rear axle tube with the

help of arm D

• The ends of stabilizer rod are placed on chassis

long members with the help of bushes

9A404.43 89
Improved Rear Suspension With Stabilizer bar

90
Rear stabilizer bar Rear Stabilizer Bar

91
Old stabilizer bar mounting

92
Old Stabilizer Bar Mounting

93
New stabilizer bar mounting

9A404.43 94
New Stabilizer Bar Mounting

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Shock absorber

96
What is the necessity of shock absorber in

the suspension system ?

9A404.44 97
 Shock Absorber

• If the suspension springs are rigid enough, they will not absorb road shocks efficiently

• If they are flexible enough, they will continue to vibrate for a longer time even after the

bumps has passed

•The springing device must be a compromise between flexibility and stiffness

• Shock absorbers are provided as part of the suspension system of motor vehicles for this

purpose

• Shock absorbers are mainly used to damp the vibrations to a reasonable level

98
Shock Absorber

Fig 1

9A404.44 99
 Shock Absorber

• When the vehicle wheel strikes a bump, the spring is compressed

• When the spring is compressed, only a little vertical upward motion is transferred to the
frame

•When the wheel comes down from the bump, the spring expands very rapidly

•If this rebound is not controlled the spring starts to vibrate heavily

• To control this vibration, shock absorber is used in the suspension system

• Similarly, when the wheel falls over a hole, the spring expands

100
 Shock Absorber
•The expanded spring unable to take the full vehicle load

• The shock absorber takes part of this load

• In the case of leaf spring suspension system, the friction between the leaves provides the
damping effect

• Because of the uncertainty of the lubrication conditions, the amount of friction also varies

•Therefore the damping characteristics do not remain constant

• Therefore, additional damping is provided by means of the dampers or shock-absorbers

•The shock absorber housing is linked to the frame cross member

• Shock absorber arm is connected to the spring axle or suspension control arm
101
Shock Absorber

Fig 2
9A404.44 102
 Shock Absorber
Shock absorbers are of two types

- Mechanical shock absorber

- Hydraulic shock absorber

Hydraulic type shock absorbers are of three types

- Van type

- Piston type

- Telescopic type

Piston type shock absorbers are classified into two types

- Single acting

- Double acting

103
Hydraulic shock absorber

104
 Hydraulic Type Shock Absorbers

• Hydraulic type shock absorbers are now used on all passenger cars

• They develop resistance to the spring action by forcing a fluid through check
valves and small holes

• In case of leaf spring the flexing of the leaves of leaf spring provides damping
effect

• In case of coil springs the whole of the damping is provided by the flexing of coil

• The hydraulic shock absorber absorbs the energy of shock through fluid by
providing damping and dissipating the same into heat

105
The principle of operation of
hydraulic shock absorber

106
 The principle of operation of
hydraulic shock absorber

Fig 1
9A404.45 107
 Operation of hydraulic shock absorber
• Piston forces the fluid in a cylinder to pass through some hole
• Due to this, a high resistance to the movement of piston is developed, which
provides the damping effect

•The hydraulic type has the additional advantage that the damping is proportional
to the square of the speed

•For small vibrations the damping is also small

• For larger vibrations the damping becomes automatically more

108
Telescopic shock absorber

109
 Telescopic Shock Absorber

• Telescopic type shock absorber is of direct acting type

• It is mounted between the axle and the frame

9A404.46 110
Telescopic Shock Absorber fitted to a Vehicle

111
Telescopic Shock Absorber
• Its upper eye ‘F’ is connected to the axle and the lower
eye to the chassis frame

• A two way valve A is attached to a rod G as shown in

figure
•Another two-way valve B is attached to the lower end of
cylinder C and tube D
• The fluid is in the space above and below the valve
A and also in the annular space between the cylinder ‘C’
and the tube ‘D

•The head ‘J’ has a gland ‘H’

• Any fluid scrapped off by the rod ‘G’ is brought down

into the annular space through the inclined passage

112
 Telescopic Shock Absorber

• The fluid generally used in shock absorbers is

a mixture of 60 percent transformer oil and

40 percent turbine oil

113
Telescopic Shock Absorber
Working:
• When the vehicle comes across a bump the lower eye moves up

• When the lower eye moves up the fluid passes from lower side of the
valve A to its upper side
• The volume of the space above valve A is less due to the volume of
the rod ‘G’
• Due to this, fluid exerts pressure on the valve B and go to the under
side of valve ‘B’
• When the lower eye ‘E’ moves down, the fluid passes from the upper side of
the Valve A to the lower side
• This passing of the fluid through the valve openings provides the damping
force

114
Telescopic Shock Absorber
Working:
• Also from the lower side of the valve B to its upper
side
• Tube ‘D’ is not full of fluid. There is air above the
fluid
• As the fluid is forced to flow through the holes in the
valves into the tube ‘D’, it has turbulence
• This operation decreases the fluid viscosity
• To prevent this gas charged shock absorbers have
been developed

115
Detailed Construction of the Telescopic Shock
Absorber

116
 Telescopic Shock Absorber

Working:

• The modern telescopic shock absorbers are no longer serviced

• If they leak or do not offer proper resistance they should be replaced

117
Twin - tube Shock Absorber

118
Air suspension system

119
 Air Suspension System
• Air spring suspension is becoming more popular now-a-days, because

of certain advantages they possess over the conventional suspension

system

120
Advantages of Air suspension system are

• A variable space for wheel deflection is put to optimum use by virtue of the automatic control devices

• Because the vehicle attitude is also constant, changes in headlamp alignment due to varying loads
are avoided

•The spring rate varies much less between the laden and unladen conditions, as compared with that

of conventional springs. This reduces the dynamic loading

•The improved standard of ride comfort and noise reduction attained with air springs

• Which also reduces both driver and passengerfatigue

121
 Air Suspension System

Types of air springs

- Bellow type

- Piston type

9A404.47to48 122
 Types of Air Springs

Bellow type Piston type

Fig 1

9A404.47to48 123
Air Spring

9A404.47to48 124
Air Spring

9A404.47to48 125
LAYOUT OF AN AIR SUSPENSION SYSTEM

126
 Layout of an Air Suspension

Fig 2
9A404.47to48 127
 Air Suspension System
working

• It consists of four air springs, which may be either the bellows type or the piston type

• These are mounted on the same position where generally the coil springs are mounted

• An air compressor takes the atmospheric air through a filter

• This air is compressed to a pressure of about 20kg/cm2, at which pressure the air in the

accumulator tank is maintained

•It is also provided with a safety relief valve.

• This high pressure air goes through the lift control valve and the leveling valves, to the air

springs

128
 Air Suspension System
Working:

• The lift control valve is operated manually

• It is operated by means of a handle on the control panel, through a cable

running from the valve to the handle

•Internal volume of the bellows is reduced during bounce, which means

that the air pressure inside the spring is increased as it is compressed i .e
the spring becomes stiffer.

•Due to this the optimally comfortable ride is provided under all conditions.

129
Air Suspension System

• A vehicle with electronic air suspension can provide about three times softer ride as

provided by conventional coil springs.

• Each air bag is filled with compressed air which supports the weight of the vehicle

• The air gets further compressed and absorbs the shock when the wheel encounters a
bump on the road

• The air is admitted into the four bags through two circuits
• In one circuit the air pressure is reduced to 12kg/cm with the help of regulator
• This pressure is admitted into the four air bags through leveling valves

130
 Air Suspension System
• Whenever there is in sufficient air in an air bag that side of the car will ride row

• This state shall cause the leveling arm to move, through linkages, there by
opening the valve and admitting more air

• The other circuits have a supply of air at 20kg/cm2 which is used to correct
additional loading of the car

• This circuits maintains the vehicle level, irrespective of whether there are
passengers or not

131
 Air Suspension System

• The other circuits have a supply of air at 20kg/cm2 which is used to correct additional loading
of the car

• This circuits maintains the vehicle level, irrespective of whether there are passengers or not

• The air at 20kg/cm2 pressure is admitted into the leveling valves through the solenoid valve

• The air is fed into the low air bag which has been compressed by added weight by the leveling

valve, when the load is decreased from the air bag to lower it to the proper level

132
Air Suspension fitted to the Vehicle

133