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Simulation Study of Design and Modification of Spring Suspension System

Article in Journal of Advanced Research in Dynamical and Control Systems · November 2019
DOI: 10.5373/JARDCS/V11I11/20193194

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Simulation Study of Design and Modification of Spring Suspension System

Article in Journal of Advanced Research in Dynamical and Control Systems · November 2019
DOI: 10.5373/JARDCS/V11I11/20193194

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Jour of Adv Research in Dynamical & Control Systems, Vol. 11, No. 11, 2019

Simulation Study of Design and Modification

of Spring Suspension System
K. Qusai, Department of Mechanical Engineering, Al-Hawija Technical Institute, Northern Technical University, Iraq.
E-mail: kamelqusay44@gmail.com
Ayad A. Ramadhan, Department of Mechanical Engineering, Al-Hawija Technical Institute, Northern Technical University, Iraq.
Ahmed M. Abbas*, Department of Mechanical Engineering, Al-Hawija Technical Institute, Northern Technical University, Iraq.
Abstract--- A damper is a automatic gadget intended to soft out what's more, disperse active power. The dampers
obligation is to disperse energy. Inside a vehicle, it lessens the impact of going over unpleasant land, prompting
enhanced traverse quality, and increment in console because of generously diminished amplitude of unsettling
influences. At the point at the point when a vehicle is going on a level street and the wheels beat a knock, the spring
is packed rapidly. The packed spring will endeavor to come back to its typical stacked length and, in this manner,
will bounce back past its ordinary stature, making the body be lifted. The heaviness of the vehicle will at that point
drive the spring down beneath its typical stacked stature. This, thus, makes the spring bounce back once more. This
ricocheting process is rehashed again and again, somewhat less each time, until the all over development at long last
stops. In the event that ricocheting is permitted to go uncontrolled, it won't just purpose an awkward ride yet will
make treatment of the vehicle exceptionally troublesome. The structure of spring in postponement framework is
significant. In this examination a spring-damper is structured and a 3D copy is made utilizing strong works
programming. The model is likewise distorted by changing the depth of the spring. Essential investigation is done on
the spring-damper by changing material for spring, Spring Steel and Beryllium Copper. The examination is finished
by thinking about burdens, bicycle weight, single individual and 2 people. Basic examination is complete to approve
the quality and modular investigation is done to decide the relocations for various frequencies for number of modes.
Examination is accomplished for two materials to check best material for spring in damper.
Keywords--- Solid-works, Suspension System, Design, Spring-damper.

I. Introduction
The shock absorbers are a significant piece of car suspension system that affect ride qualities, for example,
driving wellbeing and ride comfort. As many companies compete today working on the comfort of the passenger
and will ensure the safety of the basic principle for fabrication.
In each moving vehicle there must have a decent suspension to assimilate the stun of the tires and wheels
meeting knocks and gaps in the street. The vitality of street stun makes the spring waver; this swaying is confined to
a sensible stage by Safeguard.[1]
Vijayeshwar BV. et al. [2] they assessed the assembling of helical curl suspension springs according to necessity
by near study and examination of suspension helical circle spring. In this study two distinct materials like Chrome
Silicon and Hard drawn carbon steel have been presented. They utilized Genius/E Creo 2.0 and examination of
pressure and redirection by ANSYS 15.0 program. The hypothetical study and ANSYS results shows that Chrome
silicon spring steel is the ideal reasonable material with low weight and high firmness for helical spring applications
similar to mono stagger suspensions in bicycles and some more. N. Sai Kumar and Prof. R. Vijay Prakash [3] they
have analyze and design the exhibition of the safeguard by changing the distance across of loop wire of spring. They
utilized chrome vanadium steel of spring materials to decide the investigation of greatest shear stress, normal strain
most extreme chief stress, strain, normal strain, most extreme standard strain, absolute misshapening are noted.
Dampers are utilized in the suspension system to check any continuous vibration which may pursue the
underlying power on the system. Dampers are vital in light of the fact that springs don't "settle down" sufficiently
quick. After a spring has been packed and discharged, it limits to abbreviate and stretch, for a period this is the thing
that occurs if the spring in the driver's seat isn't controlled. [4].Pneumatic and water powered suspension systems
ordinarily appear as a chamber with a sliding chamber inside. The chamber is loaded up with a liquid, (for example,
water powered liquid) or air. This liquid filled cylinder/cylinder mix is a dashpot. The suspension systems obligation
is to ingest or disperse energy. One plan thought, when structuring or picking a suspension system, is the place that
energy will go. In many dashpots, energy is changed over to warm within the gooey liquid. In water driven

DOI: 10.5373/JARDCS/V11I11/20193194
ISSN 1943-023X 250
Received: 16 Sep 2019/Accepted: 16 Oct 2019
Jour of Adv Research in Dynamical & Control Systems, Vol. 11, No. 11, 2019

cylinders, the pressure driven liquid will warm up, while in air cylinders, the tourist is normally depleted to the air.
In different sorts of dashpots, for example, electromagnetic ones, the scattered force can be put away and utilized in
a while on. When all is said in done terms, suspension systems help pad vehicles on uneven roads [5].
Suspension systems are a significant piece of car and cruiser suspensions, aircraft landing gear, and the backings
for some modern machines. Huge suspension systems have likewise been utilized in basic manufacturing to
diminish the helplessness of structures to tremor harm and character [6].
In a vehicle, it diminishes the impact of going over unpleasant ground, prompting better traverse quality, and
increment in calm because of considerably decreased amplitude of aggravations. Without dampers, the vehicle
would have a ricocheting ride, as energy is put away in the spring and afterward discharged to the vehicle,
potentially surpassing the permitted scope of suspension development. Manage of unreasonable suspension
development without damper requires stiffer (higher rate) springs, which would thusly provide a brutal journey.
Dampers license the utilization of delicate (lower rate) springs while controlling the pace of suspension development
in light of knocks [7].
Applied to a structure, for example, a structure or scaffold it might be a piece of a seismic retrofit or as a major
aspect of new, trembling safe development. In this submission it permits yet controls activity and assimilates
thunderous energy, which can cause over the top action and inevitable auxiliary disappointment.
Damper Types
There are various strategies for changing over an effect/collision into generally flat padded contact [7].
• Metal Spring
• Rubber Support
• Hydraulic Dashpot
• Collapsing wellbeing dampers
• Pneumatic Chambers
• Self remunerating Water driven
However the scope of work of this paper is restricted to Metal Spring damper type only.
Metal Springs
Basically finding metal springs to assimilate the effect loads are an ease technique for diminishing the collision
speed and lessening the stun stacking. They can work in challenging conditions under a wide scope of temperatures.
These gadgets have high halting powers at end of stroke. Metal springs store energy as opposed to disseminating it.
In the event that metal spring type dampers are utilized, at that point measures ought to be given to confine Motions.
Metal springs are regularly utilized with thick dampers.
There are different sorts of metal springs including helical springs, incline washers (cone-springs), leaf springs,
ring springs, work springs, and so forth. Each spring sort has its own working qualities [8].
The shock absorber performance was designed and tested by some researchers [9]. with changing the diameter of
the spring wire. A pulsed spring was used, made of cast iron and vanadium steel, where the amount of shear stress
was measured with the amount of deformation after loading. A comparative study [9] was conducted of the spiral
springs according to the different materials used for shock absorption. The analysis was carried out using the Fainite
Mint program by ANSIS. The materials used in this field were made of carbon steel, stainless steel and chrome
vanadium. Stresses and distortions Absorption of shocks by springs for vehicles is very important to overcome the
sudden and concentrated stresses on the vehicle to prolong the life of the mechanical parts made of the composite.
This is done in this study by changing the diameter of the spring wire in addition to studying the change in the type
of materials used in the springs [10] Ragupathip
Vinnai [11] used three different materials in the manufacture of springs in this study are: Steel Vandium,
castings and stainless steels and a fixed load of 850 net and the best conditions for the removal of spring through the
results of stresses and distortions resulting from those loads for the same conditions. Christopher et al.used [12]
ANSYS program to analyze and study the change of diameter of wire and dimensions and its impact on the amount
of stresses and distortions in the springs.
The aim of the this research is to simulate and compare between the springs that making of two different metals
using solid work software and to approve the quality and modular investigation is done to decide the removals for

DOI: 10.5373/JARDCS/V11I11/20193194
ISSN 1943-023X 251
Received: 16 Sep 2019/Accepted: 16 Oct 2019
Jour of Adv Research in Dynamical & Control Systems, Vol. 11, No. 11, 2019

various frequencies for number of modes. Additionally Correlation is cultivated for two materials to confirm best
material for spring in damper.

II. Methodology
2.1 Material Selection and Properties
In this study, samples were selected from Spring Steel and Beryllium Copper with the following specifications
and dimensions according to the table (1). The study was done by changing the diameter of the wire from 8 to 6 mm
for both metals through theoretical study using Solid Work program to find the amount of stress and elongation in
both cases.
Table 1: Generalized Parameters for Helical Spring
Generalized Parameters for Helical spring
Mean diameter of a coil (D) 64mm
Diameter of wire (d) 8mm
Total no of coils (n) 15
Pitch (P) 14mm
Weight of bike 125kgs
Let weight of 1 person 75Kgs
Weight of 2 persons = 75×2 150Kgs
Weight of bike + persons 275Kgs
Considering Factor of Safety(FOS) 1.5
Weight of Bike 200 kg(including FOS)
Weight of Bike+2 persons 415 kg (including FOS)
2.2 Model of Suspension System
The previous study shows that there is limited research that is specialized in the study of springs, dampers and
metals different from that discussed in the research diameter 8 mm and 6 mm. While the current study focused on
the study of two cases of different metals; characteristics and mechanical specifications with different radius (8, 6
mm) and the effect of these factors on the stresses and deformation through the simulation of these cases by Solid
Work program. The model consists of three parts; Inner, outer damper and spring as shown in figure1 (a, b and c)
and figure (2) shows the model to be studied with the Sold Work program.

(a) (b) (c)

Fig. 1: Model Dimensions (a-Inner Part of Damper, b-Outer Part of Damper, c-Spring)

DOI: 10.5373/JARDCS/V11I11/20193194
ISSN 1943-023X 252
Received: 16 Sep 2019/Accepted: 16 Oct 2019
Jour of Adv Research in Dynamical & Control Systems, Vol. 11, No. 11, 2019

Fig. 2: Assembly of Spring-Damper

III. Results and Discussion

Two different cases were presented in this work by different metals, diameters and different weights as
following:-
1. The materials selected in this work were made of steel and Beryllium Copper.
2. Different diameter (6 and 8mm)
3. The weight used (200 kg) and (415 kg) for each case and a comparison of the results obtained by the two
radiuses as shown below.
3.1 Analysis Using Material Spring of Steel
The analysis of the spring made of the steel material was done by depending on the mechanical properties shown
in the following table (2) and within the conditions adopted in the first and second cases:
Table 2: Mechanical Properties of Steel Spring
Material Properties Young’s Modulus (EX) N/mm2 Poisson’s Ratio (PRXY) Density kg/mm3
Value 210000 0.29 0.000007850
The results obtained by using Sold work program to test the behavior of spring made from steel material with
Von Mises and Deformation criteria for weight (200 kg) as shown in Figure (3). The results showed that the highest
stress value (6.58 Mpa) and the lowest value was (0 Pascal), While the distortion value between (0-7.6715 μm)

Von Mises Stress Deformation

Fig. 3: Load 200kgs, Bike Weight Inclusive FOS
In the second case, the load was changed with the weight of the persons at a total weight of (415 kg) as shown in
Fig. 4 and showed an increase in stress where the highest stress value was 13.654 Mica Pascal and the lowest value
was 0 Pascal. 15.918 micrometers). In comparison with the above figure, we notice an increase of 51.8%.

DOI: 10.5373/JARDCS/V11I11/20193194
ISSN 1943-023X 253
Received: 16 Sep 2019/Accepted: 16 Oct 2019
Jour of Adv Research in Dynamical & Control Systems, Vol. 11, No. 11, 2019

Von Mises Stress Deformation

Fig. 4: Load 415kgs, Bike Weight + Weight of 2 Persons Inclusive FOS
3.2 Analysis using material Beryllium Copper
The second model of metal was selected as beryllium magnification according to the mechanical characteristics
shown in the following table (3) and under the conditions adopted in the first and second cases (change of weights)
and in the same dimensions. Different results were obtained for beryllium cooper and for both cases (200 kg) in Fig.
(5) and weight (415 kg) in Fig. (6).
Table 3: Mechanical Properties of Beryllium Copper Spring
Material Properties: Young’s Modulus (EX)N/mm2 Poisson’s Ratio(PRXY) Density kg/mm3
Value 280000 0.285 0.000001850

Von Mises Stress Deformation

Fig. 5: Load 200kgs, Bike Weight Inclusive FOS

DOI: 10.5373/JARDCS/V11I11/20193194
ISSN 1943-023X 254
Received: 16 Sep 2019/Accepted: 16 Oct 2019
Jour of Adv Research in Dynamical & Control Systems, Vol. 11, No. 11, 2019

Von Mises Stress Deformation

Fig. 6: Load 415kgs, Bike weight+Weight of 2 persons inclusive FOS
The results showed that the highest value of stress in the case of the weight of 200 kg is (6.580 MPa) and the
lowest value (0 MPa) while in the case of weight 415 kg, the highest value (13.654 MPa) and the lowest value (0
Mpa) Similar to 51.8% steel case.In the case of distortion at a weight of 200 kg, the values of the deformation
ranged between (0 - 7.6715 μm) while the weight (415 kg) values ranged from (0-15.918 μm) and increased by
51.8%. The above results show the difference between the case of steel and the condition of beryllium due to the
difference in the mechanical properties of elasticity and material density of the models used with diameter 8 mm in
this research.
3.3 Modified Design-Analysis Using material Spring Steel
The diameter of the spring was changed from 8 mm to 6 mm and the two weights for the metals (steel, beryllium
cooper) with the same characteristics mentioned in Table 2 were obtained. The results obtained from fig (5) for a
weight of 200 kg where presented of stresses ranging with (0-6.580 Mpa). While, the results showed that the highest
value of stress (6,597 MPa) and the lowest value was (0.0014172 Pascal) while the value of the variance between (0
- 7.59 μm) as shown in fig(7).

Von Mises Stress Deformation

Fig. 7: Load 200kgs, Bike Weight Inclusive FOS

DOI: 10.5373/JARDCS/V11I11/20193194
ISSN 1943-023X 255
Received: 16 Sep 2019/Accepted: 16 Oct 2019
Jour of Adv Research in Dynamical & Control Systems, Vol. 11, No. 11, 2019

In the second case, the load was changed with the weight of the persons at a total weight of (415 kg ) as shown in
Fig. 8 and showed an increase in stress where the highest stress value was (13.69 MPa) and the lowest value was
(0.0023239 Pa) with (15.75 μm) deformation value. In comparison to the above, we notice an increase of 51.8%

Von Mises Stress Deformation

Fig. 8: Load 415kgs, Bike Weight + WEIGHT of 2 Persons Inclusive FOS
3.4 Analysis using material Beryllium Copper
The second metal was selected as Beryllium magnification according to the mechanical characteristics that
presented in the first and second cases (change of weights) and in the same dimensions. Different results were
obtained for beryllium cooper and for both cases (200 kg) in Fig. (9) and weight (415 kg) according to Fig.(10).

Von Mises Stress Deformation

Fig. 9: Load 200kgs, Bike Weight Inclusive FOS

DOI: 10.5373/JARDCS/V11I11/20193194
ISSN 1943-023X 256
Received: 16 Sep 2019/Accepted: 16 Oct 2019
Jour of Adv Research in Dynamical & Control Systems, Vol. 11, No. 11, 2019

Von Mises Stress Deformation

Fig. 10: Load 415 kgs, Bike Weight + Weight of 2 Persons Inclusive FOS
The results showed that the highest value of stress in the case of the weight of 200 kg (7.9959 mica Pascal) and
the lowest value (0.00131 pascal) while in the case of weight 415 kg as shown in Figures. (10 and 11) below, the
highest value (16.592 MPa) and the lowest value (0.002141 Pascal) Similar to 51.8% steel case. In the case of
distortion at a weight of 200 kg, the values of deformation ranged between (0 - 7.5767 μm) while the weight (415
kg) values ranged from (0-15.722 μm) and increased by 51.8% as shown in figures (12 and 13). The above results
show the difference between the case of steel and the condition of beryllium due to the difference in the mechanical
properties of elasticity and material density of the models used with diameter 8 mm in this research.

Fig. 11: The Stress Comparison between Steel and Beryllium Copper Materials of (415kg) with 6mm and 8mm

Fig. 12: Deformation Comparison between Steel and Beryllium Copper Materials of (415kg) with 6mm and 8mm

DOI: 10.5373/JARDCS/V11I11/20193194
ISSN 1943-023X 257
Received: 16 Sep 2019/Accepted: 16 Oct 2019
Jour of Adv Research in Dynamical & Control Systems, Vol. 11, No. 11, 2019

Fig. 13: The Stress Comparison between Steel and Beryllium Copper Materials of (200kg) with 6mm and 8mm

Fig. 14: Deformation Comparison between Steel and Beryllium Copper Materials of (200kg) with 6mm and 8mm

IV. Conclusion
1. To approve the quality of our plan, we have done auxiliary examination on the damper. We have done
investigation by changing spring material Spring Steel and Beryllium Copper.
2. By watching the examination outcome, the investigated pressure esteems are not exactly their separate give
up pressure esteems. So our plan is sheltered.
3. By looking at the outcomes for the two materials, the pressure esteem is less for Spring Steel than Beryllium
Copper.
4. Also the damper plan is adjusted by lessening the breadth of spring by 2mm and auxiliary investigation is
done on the damper. By diminishing the width, the heaviness of the spring decreases. By contrasting the
outcomes for the two materials, the pressure esteem is less for Spring Steel than Beryllium Copper.

DOI: 10.5373/JARDCS/V11I11/20193194
ISSN 1943-023X 258
Received: 16 Sep 2019/Accepted: 16 Oct 2019
 Jour of Adv Research in Dynamical & Control Systems, Vol. 11, No. 11, 2019

5. By looking at the outcomes for present structure and changed plan, the pressure and uprooting values are not
as much of for altered plan.
6. So we can infer that according to our investigation utilizing material spring steel for spring is ideal and
furthermore our changed structure is protected.

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DOI: 10.5373/JARDCS/V11I11/20193194
ISSN 1943-023X 259
Received: 16 Sep 2019/Accepted: 16 Oct 2019

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