Need of suspension system in Automobiles

Need of suspension in motor vehicle:

1) To absorb and damps various vibrations, oscillations and shocks.
2) To transmit braking and driving torque to body frame.
3) To support the body on axles.
4) To provide appropriate road grip.
5) To avoid excessive rolling, pitching and bouncing.
6) To provide stability on slopes and turns.
7) To provide maximum comfort to the driver and passenger .
 Requirements of suspension system
1. There should be minimum deflection.
2. It should be of low initial cost.
3. It should be of minimum weight.
4. It should have low maintenance and low operating cost.
5. It should have minimum tyre wear.
 Suspension system
Types of suspension system
1. Rigid Axle Suspension system:
a) Leaf spring b) Torsion bar

2. Independent Suspension system:

a) For Front Axle: i) Wishbone Type ii) Mac Pherson Strut Type iii) Vertical Guide
Type iv) Trailing Link Type v) Swinging Half Axle Type
b) For Rear Axle: i) De Dion Axle Type ii) Trailing Link Type iii) Link Trailing Arm
Type
3. Shock Absorber:
a) Single and Double acting b) Twin and Mono tube c) Hydraulic and Gas filled.
Rigid Axle Suspension system
The upward suspension travel that compresses the spring and shock absorber
is called the jounce, or compression.
The downward travel of the tire and wheel that extends the spring and shock
absorber is called rebound, or extension.
Coil Spring
 Leaf spring suspension
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 ends of the leaf are fixed, then it will not able to accommodate this
change in length. Hence a shackle is provided at one end and another end is
bracketed to frame. Since the front end is fixed, the leaf spring has a center of
rotation at the front fixed end. Also the propeller shaft is connected to the
universal joint near the front end. Thus, leaf spring and propeller shaft (with rear
axle) swivel around the front end while the shackle permits this swiveling of the
rear eye of the leaf. When the leaf spring deflects, the upper side of each leaf rubs
against adjacent surface of the other leaf. This provides the damping effect.
Leaf spring suspension
 Types of Leaf Springs

1.Full – elliptic type

2.Semi – elliptic type
3.Quarter – elliptic type
4.Three Quarter – elliptic type
5.Transverse Spring type
6.Helper Spring type
Function of helper spring and shackle in leaf spring.
Helper spring
1) Helper spring is just like a semi elliptical spring but without eyes at the end
Its end touches the bracket to take heavy load in addition to the main leaf spring
2) Its function is to cushion the vehicle and passengers
3) It store energy while travelling from road irregularities and road bumps and
release energy to come back its original position
4) Cost of implementation is lower and not complicated.
5) It provides more rigidity to frame, avoiding distortion.
Functions of shackle in leaf spring
1) A shackle is an integral component of the suspension system that attaches
between the leaf spring and the vehicle frame. It allows for the leaf spring to
accommodate the change in length of leaf spring during suspension articulation.
2) The axle will rotate downwards at the shackle side, so pinion angle will be
increased
3) The shackle mount will provide increased leverage
4) Suspension down travel will be increased, but up travel could be limited slightly.
5) Shackle improves vehicle function by providing more room for larger wheels and
tires as well as increased ground clearance for off road use.
 Wishbone type suspension
Construction: It consists of upper and the lower wishbone arms provided to
the frame. These arms resemble letter ‘A’. The spring is placed in between the
lower wishbone and the underside of the cross member. The vehicle weight is
transmitted from the body and the cross member to the coil spring through
which it goes to the lower wishbone member. A shock absorber is placed inside
the coil spring and is attached to the cross member and to lower wishbone
member.

Working: When the vehicle came across a bump and wheel is tended to move
up the lower and the upper arm moves up and the coils spring is compressed,
so shock absorber (Damper) damps the vibrations setup in the coil spring due
to road irregularities. After passing over a bump the lower arm comes to its
original position with upper arm. This type of suspension resists up and down
forces that develop after bump, acceleration, braking and cornering.
Wishbone type suspension
Wishbone type suspension
 Macpherson suspension system
Mc-pherson strut type independent suspension: In this type, only lower
wishbones are used as shown in fig. A strut containing shock absorber and the
spring carries also the stub axle on which the wheel is mounted. The wishbone
is hinged to the cross member and positions the wheel as well as resists
accelerating, braking and side forces. This system is simple, lighter and keeping
the unsprung weight lower. Further the camber also does not change when the
wheels move up and down. This type of suspension provides the maximum area
in the engine compartment and is, therefore, commonly used on front wheel
drive cars.
The advantages of MacPherson suspension system
1) System is light in weight, which reduces un-sprung weight.
2) Camber does not change when wheel moves up and down.
3) It provides maximum space for engine.
Macpherson suspension system
Air suspension system
Air suspension system
 Shock absorber

A shock absorber is a device used to check or damp out the vibrations of the
suspension springs to a comfortable level.
• The resistance to the free oscillation of the springs is obtained in the
damper by causing a fluid to pass at high speed through small holes.
• The energy absorbed depends upon the viscosity of the fluid and appears as
heat in the fluid.
 Types of shock absorbers

Classification by operation:
a). Single action shock absorber
b). Multiple action shock absorber.
• Classification by construction:
a). Mono tube shock absorber
b). Twin tube shock absorber
• Classification by working medium
a). Hydraulic shock absorber
b). Gas filled shock absorber
 Telescopic shock absorber
Below figure shows a simple Telescopic Shock absorber. There is a fluid in space
above valve assembly (A), below (A) & also in annular space between cylinder
(C) & tube (D), which is connected to the space below valve assembly (B). (H) is
gland in head (J) & any fluid scrapped off by rod (G) is brought down into
annular space through inclined passage shown in head. Eye (E) is connected to
axle, while eye (F) is attached to chassis frame. Fluid generally used in shock
absorbers is a mixture of 60 per cent Transformer oil & 40 per cent Turbine oil.
When car has come across a bump, Eye (E) would move up & thereby the fluid
will pass from lower side of valve assembly (A) to its upper side. Due to pressure
of fluid through rod (G) fluid will be go to underside of valve (B). This passing of
fluid through valve openings provides damping. Similarly for downward motion
of eye (E), fluid will pass upper side of valve assembly (A) to lower side & also
from lower side of valve assembly (B) to its upper side.
 Gas filled shock absorbers

Rapid movement of the fluid between the chambers

cause foaming.
Results in a lag because the piston moves through an
air pocket which offers resistance.
Foaming results in a decrease of damping and a loss
of
spring control.
Pressure increases in front of the piston and drops
behind it.
 Wheels and Tyres
Wheels
Wheels along with the tyre has to take the vehicle load, provide a cushioning effect
and cope with the steering control.
• Various requirement of an automobile wheels are:
1. Strong enough to perform the above functions.
2. Balanced both statically and dynamically.
3. Possible to remove or stand the vehicle wheel easily.
4. As lightest as possible so that the un-sprung weight is least.
5. Easy to clean, easy to wash and be of good quality.
6. Should not deteriorate with age and weathering. If material is
vulnerable to corrosion, must be given suitable protective
treatment.
7. must be of maximum strength to take the weight road shocks,
driving torque and must be able to compensate all sorts of load
varying in magnitude and direction.
8. must be strong enough to resist local deformation or when it hits
The obstacle.
TYPES OF AUTOMOBILES WHEELS
1. PRESSED STEEL DISC
2. WHEELS WITH STEEL WIRE SPOKES
3. LIGHT ALLOY CASTING WHEELS.

1. PRESSED STEEL DISC

Most popular and most used types of wheel.
• Strong, light, stiff and resistant to accidental damage.
• Can be manufacture in mass at a very economical low cost.
• These type of wheel has two pressings namely the rim and the disc
member wielded together.
 2. WHEELS WITH STEELWIRE SPOKES

 It is Oldest in design but remained in use

largely because of light weight and
strong construction but costly.
 Rim attached to the hub through
wire spokes.
 Much stronger in tension and transmit
all the forces to the rim.
 Spoke has very little resistance to the
bending, fastened so that complex
loads coming on the wheels are resolved
into tensile load evenly
distributed among the adequate number
of spokes.
 The stress and loads faced by car wheel
are very complex, more critical in
cases such as accelerating, braking and cornering
and when such action is required. More often the spokes have different sets
to take the acceleration, braking and weight forces.
 Also able to take the side thrust during cornering by having a triangular
pattern.
 3. LIGHT ALLOY CASTING WHEELS.
It is made from casting of light alloys of aluminium and magnesium.
• Wider rims and radial ribs, also acts as angled spokes to provide
strength and air circulation.
• Construction avoids any sharp lines and angles to improve strength.
• Disadvantages over the other two, specially use in racing car.
• Aluminium and magnesium are usually.
• It is Light in weight.
• Heavier sections can be used to improve the stiffness of the wheel and
result in better stress distribution.
• Rims with larger area can be used, results in the use of wider tyres with
less diameter, an absolute advantage in racing car since the lower centre of
gravity and wider tyres result in better road grip particularly during
cornering.
• Better conductor of heat and hence heat dissipation from tyres and brakes
is improved.
• Only corrosion is the main problem, chemically sensitive to salt spray and
need regular checking and inspection for corrosion.
3. LIGHT ALLOY CASTING WHEELS.
 Tyres
Functions
1.Only contact with ground
2.Act as the primary suspension, cushioning the vehicle from effects of rough
surface.
3.Provide frictional contact with the road surface which allows the driving wheels
to move the vehicle
3.Front tyres allows the wheels to steer
4.Rear tyres allow braking to slow or stop the vehicle

Properties of tyres
NON SKIDDING :-Tread pattern on the tyre must be suitably designed
to permit the least amount of skidding.
• UNIFORM WEAR :-To maintain the non-skidding property, the wear
on the tyre tread must be uniform. The ribbed pattern on the tyre
help to accomplish this.
• LOAD CARRYING:-Tyre material and the design must be able to
ensure that the tyre is able to sustain stresses developed in all
conditions.
• CUSHIONING :- Tyre should be able to absorb small high frequency
vibration set up by the road surface and thus providing cushioning
effect.
POWER CONSUMPTION :- The automotive tyre absorb some power
due to friction between the tread rubber and the road surface and
also due to friction loss on account of the tyre being continuously
fixed release, should be least as less as possible.
• TYRES NOISE :- Tyre noise may be in the form of definite pattern sing,
a sequel, or aloud sound, Should be minimum.
• BALANCING :- As a rotating part of automobile, must be balance
statically and dynamically.
Tyre Cutaway
 Radial Ply Tyre

Radial Ply Tyre Construction

1.Plies run straight across from

bead to bead.
2.Has a very flexible sidewall and a stiff tread,
giving it a very stable footprint
3.Consist of a carcass ply formed by textile arcs
running from one bead to the other.
4.Each ply is laid at an angle of 90 degrees to
the direction the tyre rolling
5.At the top of the tyre crown (under the tread),
a belt made up of several plies reinforced with
metal wire is laid.
6.These crown plies, laid one on top of the other,
overlap at an angle determined by the type of the tyre.
Advantages of Radial Ply Tyres
1.Side walls can bend easily, its shock absorbing capacity is 25% more than
bias ply or cross ply.
2.Lower rolling resistance and friction loss leads to less fuel consumption
3.Longer tread life because of less heat build in tyre.
4.Breaking efficiency on wet roads is better because of greater sidewall
flexibility and tread stiffness.
5.Better steering characteristics.
6.While taking turns it has less tendency to distort and lift off the road from
one side.
7.Larger resistance to punctures ,cuts and impacts in the tread area.
 Cross-Ply Tyre

1.Ply cords are woven at angle of 30 to 40 degree to the tyre axis.

2.One of the oldest design
3.Several textile plies are laid across each other, running from bead to bead in
alternate directions
4.Number of plies depends on the size of the tyre and the load it has to carry
5.Does not use belts
6.Allows body of the tyre to flex easily
7.Improved cushioning, hence smooth ride on rough roads
 Factors Affecting Tyre Life

1.Inflation
2.Vehicle maintenance
3.Manner of Driving
4.Miscellaneous factors
 Under inflation AND Over inflation
Effect of under inflation:
1) Uneven tread wear, more wear at the tyre sides.
2) Lack of directional stability
3) Increased rolling resistance leading to increased fuel consumption
4) The valve may be ripped out due to tyre sides.

Effect of over inflation:

1) Reduced tread contact area with the road surface. This result in rapid wear
in the tread at the center.
2) Reduced tyre grip.
3) Reduced impact resistance.
4) Increased vibrations resulting in uncomfortable ride.
5) Increased stresses may causes tread separation & crack in the side walls.
Under inflation Over inflation
Comparison between tubed tyres and tubeless tyres

Tubed tyres Tubeless tyres

Difference between radial and cross ply tyres
 Tyre specifications
185/60 R 14 82 H

185-The tyre section width in millimeters

60-The aspect ratio in % (the height of the sidewall divided by the tyre's width)
R-Denotes the tyre's construction type – (in this case it's a radial)
14-Rim diameter in inches
82-Load Index
H-Speed Rating
 Li kg Li kg
Speed Maximum 65 290 94 670
symbol speed km/h mph 66 300 95 690
N 140 87 67 307 96 710
P 150 93 68 315 97 730

Q 160 99 69
70
325
335
98
99
750
775
R 170 106 71 345 100 800
S 180 112 72 355 101 825
T 190 118 73 365 102 850

H 210 130 74 375 103 875

V 240 149 75 387 104 900

76 400 105 925
W 270 168 77 412 106 950
Y 300 186 78 425 107 975
ZR 240 149 79 237 108 1000
80 450 110 1030
81 462 110 1060
82 475 111 1100
83 487 112 1120
84 500 113 1150
Speed Rating 85 515 114 1180
86 530 115 1215
87 545 116 1250
88 560 117 1285
89 580 118 1320
90 600 119 1360

91 615

92 630
Load Index
93 650
 Causes of tyre wear and remedies

Causes of tyre wear and remedies:-

1) Incorrect inflation –ensure correct tyre pressure.
2) Excessive braking and violent acceleration ---avoid rash driving
3) Worn king pins--------replace it.
4) Misalignment ------ensure wheel alignment.
5) Wrong loading ----- ensure proper loading
6) Toe-out incorrect on turn----- ensure wheel alignment
7) Careless driving --- ensure proper driving
8) Incorrect caster ,camber or toe in ------ensure wheel alignm
9) Damaged beads--- ensure proper driving
10) Bleeding of air in tyre---------ensure valve
11) Out of balance wheel-------- ensure wheel alignment
 Wheel Alignment
Wheel Alignment
The alignment is concerned with the wheels being perpendicular to the
surface of the road and that the wheels are parallel to each other. This
means that the car will drive evenly. It allows the vehicle to go down the
road as straight as an arrow with no one side being overly stressed. Proper
alignment can also allow for quicker stops and a shorter distance to cause
that stop.

Wheel Alignment Angles

1. Camber
2. Caster
3. Toe
4. Steering Axis Inclination
5. Turning Radius
 Necessity of wheel alignment and wheel balancing

The necessity of wheel alignment

1) To eliminate tyre wear
2) To give vehicle proper handling
3) To eliminate pull, drift, stiff steering and poor steering return ability
4) To improve driving stability
5) To improve riding characteristics
The necessity of wheel balancing
1) Wheel imbalance causes wheel tramp, wheel hop, makes the tyre vibrate
up and down
2) Centrifugal forces try to throw heavy areas outward when the wheel is
spinning
3) Weight must be evenly distributed around the axis of rotation
4) Wheel balancing is necessary to balance the wheel and distribute the
weight of wheel evenly.
 Wheel Balancing and its procedure.

Wheel balancing:
It is a process that ensures wheel spins truely as they are fitted on a vehicle. In
case wheel are not spinning properly then there are problems like uneven tyre
wear, a vehicle pulling on one side, excessive bouncing of a vehicle which we
face. To avoid them this is done. Wheel balancing means balancing wheel
around axis around which it rotates.

Procedure of dynamic Wheel Balancing:

Fill tyre with recommended tyre pressure, check for tyre / wheel
damage don’t use damaged rim for balancing
1.Mount wheel on balancing Machine and lock it. Remove old balance weights.
2. Set balance for size of tyre and start the machine.
3. Read values of imbalance on right and left side of wheel on display.
4. Put respective weights on both sides on marks.
5. Start balancer again and check that reading is zero on both sides then the
wheel is balanced.
6. If reading on both sides is not zero then repeat the procedure.
Benefits of Wheel Balancing

1.Wheel balancing will ensure a smoother ride and more enjoyable driving.
2.The tires and wheels to spin without causing any vibrations
3.The better wear from the tyres will save you time and money
4.Vibration free that is comfortable to drive in and easy to handling of the
vehicle.
5.Remove stresses and strains on the wheel bearings and suspension
components
6.Steering components can be safe and prevent from failure of prematurely
extreme cases to all the parts
7.Protect from premature wearing of suspension and steering components,
rotating parts and tyres.
8.Save from any dangerous and expensive