:2023-24

DANIEL MOHAPATRA
ROLL NO: 2305090021
SUBJECT: ENGINEERING SOFTWARE LAB
MECHANICAL ENGG(MDA)

DR. JYOTI RANJAN MOHANTY

`PROF. OF MECH DEPT

VEER SURENDRA SAI UNIVERSITY OF

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ABSTRACT:
As we know, vehicles bear a logical damage on their suspension when
having harsh roads. The conditions of road is so bad that it may damage
the suspension easily in form of fatigue. Here many cycles of shock takes
place, and hence if we don’t use a shock absorber on the
safeguard/suspension, it may leads to fracture. In this undertaking, a
safeguard is planned and a 3D model is made by using Ansys. Many
investigations is done by which it can bear weights of bicycle/bike,
burdens, or two-fold people. Also I had a sharp eye on making the material
i.e structural steel. It is corelated by using two shock absorbers on both
sides for better bearing capacity. The demonstration is being done on
Ansys.
In this paper, a shock absorber is designed and analyzed which is useful
for damping shock impulse and dissipating kinetic energy. Shock absorber
is a critical part of the suspension system, which is used to connect the
vehicle to the wheels. The purpose of the work is to model a shock
absorber which will be able to improve the ride quality by reducing the
amplitude of disturbances caused by a bump road. Shock absorber is
designed in SOLIDWORKS software. Analysis of shock absorber was
performed by using ANSYS software and this analysis helps to predict the
shock absorber failure when an external load acts on it.
Keywords- Suspension, Damping, Piston, Kinetic Energy, Vibration
control, Solidworks, Ansys.

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INTRODUCTION:
A safeguard or damper is a mechanical gadget intended to streamline or
moist stun drive, and disseminate motor vitality. Whenever any vehicle
crosses a bump on the road, shock impulse is generated which will affect
the passengers travelling in the vehicle Therefore, shock absorber or
damper is a critical part of a suspension system used to dissipate kinetic
energy and damp shock impulse. Without shock absorbers, the vehicle
will bounce ride. A shock absorber absorbs sudden shocks generated by
the uneven surface of the road and makes the ride smooth and
comfortable.
Description
The suspension system generally consists of three main components:
a structure that maintains the weight of the vehicle and determines the
geometry of the suspension; a spring that converts kinematic energy into
potential energy; or vice versa and a damper, a mechanical device
designed to dissipate kinetic energy. Shock absorbers are hydraulic
pump-type devices that help manage the impact and recoil motion of the
vehicle's springs and suspension. The main function of the shock absorber
is to ensure that the vehicle tire always remains in contact with the road
surface, which provides the safest vehicle brake control and response.
Vehicle Suspension
In a vehicle, it diminishes the impact of going over harsh ground,
prompting improved ride quality, and increment in comfort because of
considerably decreased plentifulness of unsettling influences. Without
safeguards, the vehicle would have a bobbing ride, as vitality is put away
in the spring and afterward discharged to the vehicle, potentially
surpassing the permitted scope of suspension development. Control of

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extreme suspension development without stun ingestion requires stiffer
(higher rate) springs, which would thus give a brutal ride. Safeguards
permit the utilization of delicate (lower rate) springs while controlling the
pace of suspension development because of knocks. They likewise,
alongside hysteresis in the tire itself, moist the movement of the unspring
weight here and there on the springiness of the tire. Since the tire isn't as
delicate as the springs, powerful wheel skip damping may require stiffer
stuns than would be perfect for the vehicle movement alone. Spring-based
safeguards regularly use loop springs or leaf springs, however suspension
bars can be utilized in tensional stuns also. Perfect springs alone, be that
as it may, are not safeguards as springs just store and don't scatter or retain
vitality. Vehicles normally utilize springs and suspension bars just as
pressure driven safeguards. In this blend, "safeguard" is held explicitly for
the water driven cylinder that ingests and disperses vibration.
Shock Absorber Types
There are various techniques for changing over an effect/impact into
generally smooth padded contact.
1.Metal Spring. 5. Pneumatic cylinders.
2. Rubber Buffer. 6. Self-repaying Hydraulic
3. Hydraulic Dashpot.
4. Collapsing security Shock Absorbers.

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LITERATURE REVIEW:
1. Johnson et al. has created a shock absorber design for carrying
loads of a vehicle. The shock absorber is modelled in
SOLIDWORKS software. Structural analysis is performed by
varying the material in ANSYS Mechanical APDL software. After
modelling the shock absorber, boundary conditions are applied.
Von-mises stress and deformation values are observed in the results.
2. Sudarshan et al. has developed a new methodology which allows
designing the components of a shock absorber by using FEM. In
production of shock absorbers, it is difficult to know the accuracy of
shock absorber which doesn’t fail. The shock absorber is modelled
by using SOLIDWORKS software and analysed in ANSYS
workbench by considering the weight of vehicle. In the results,
deflection and stress induced in the shock absorber are observed.
3. Bhasha et al. has designed a 3D model of shock absorber by using
CATIA V5 R21 and changed the thickness of spring. A shock
absorber reduces the effect of shocks while travelling on a rough
road and increases the ride comfort and quality by reducing the
amplitude of disturbances. Structural and modal analysis is
performed on shock absorber by considering different materials for
spring by using ANSYS software. Structural analysis was performed
to validate the strength of the shock absorber. To determine the
displacements for different frequencies, modal analysis was
performed.
4. Chavhan et al. has designed a shock absorber of pleasure vehicle.
The shock absorber is modelled using Pro- E software. By using
ANSYS software, static and dynamic analysis is performed by
changing materials for spring. In ANSYS, the results of deflection
and von-mises stress are observed.
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5. Mallesh et al. has designed a 3D model of shock absorber by using
SOLIDWORKS software and structural analysis of shock absorber
is performed by using ANSYS 15.0 software. Suspension system
consists of springs and dampers for passenger’s safety and for a
comfortable ride. A shock absorber consists of spring, top and
bottom part. The loads are applied on shock absorber to know the
results of total deformation, equivalent stress and equivalent strain.
6. Mohan et al. has modelled a shock absorber using Pro/ENGINEER
software. Structural and modal analysis is performed by considering
the vehicle weight and person weight. Modal analysis is performed
to know the displacements and frequencies for number of mode
shapes.
7. Achyut et al. has designed a 3D model of shock absorber by using
Pro/ENGINEER software. Shock absorber consists of a sliding
piston in a cylinder. The cylinder can be filled by either fluid or air.
Analysis is performed in ANSYS. The results of natural frequency,
total deformation and shear stress are observed.

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PROBLEM STATEMENT AND
METHODOLOGY:
For vehicles, it is always challenging to maintain simultaneously a high
standard of ride comfort, vehicle handling under all driving conditions. It
is necessary to determine the characteristics of damping system for
various computational and analysis purpose which can be further utilized
in Research & Development of shock-absorbers.
This project aims towards defining a universal testing procedure for shock
absorbers.
Shock absorbers will undergo a specific test sequence. All the tests will
be predefined and described in detailed. In order to properly investigate
the variable controls of a shock absorber and enable greater performance
of the suspension system, a more detailed and a universal testing
procedure is needed.
It involves analyzing the behavior of the shock absorber under various
conditions such as different loads, velocities, and road profiles. The goal
is to optimize the design to minimize vibrations, maximize energy
dissipation, and ensure durability.

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MATERIAL SELECTION AND INPUT
PARAMETER:
1.Chrome Vanadium ASTM A231 [High Carbon Steel]
- Young’s Modulus =20700 Mpa
- Density=7.86 g/m^3
- Poisson ratio=0.25
2. Structural Steel
- Young’s Modulus=200000 MPa
- Density=7.8 g/m^3
- Poisson ratio=0.29
3. Hard Drawn ASTM A227 [Alloy Steel]
- Young’s Modulus=190000 Mpa
- Density=7.8 g/m^3
- Poisson ratio=0.29
Reason for selection of these material:
1. Stiffness comparatively more than other.
2. Readily available.
3. Good corrosion resistant.
4. Hardness.

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LOAD CALCULATION:

1. Diameter of wire (d) = 7.25mm

2. Number of active coil (n) = 14
3. Weight of the bike= 125kg
4. Weight of one person = 75kg
5. Weight of two person =75*2= 150kgs
6. Bike weight + two person weight = 125+75 = 275kgs [275kg convert
to 2696.82 N]
Here by I take mention loads 1&2 for calculation,
Load = 2696.82 N

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SOLIDWORKS MODEL DESIGN:
Introduction
Mechanical design and drafting courses are basic courses for engineering
majors. According to different major, emphases of mechanical design and
drawing courses are different. However, the main purpose is to cultivate
spatial imagination ability, to guide students’ solid modeling and 3D
construction and to cultivate engineering and technical personnel for the
enterprises, who possess modern design philosophy and creative thinking
ability. The course, with a strong theoretical and practical quality is aimed
at developing students’ ability to think, analyze and raise questions about
engineering as well as improving the capacity to draw and read
engineering chartings through theoretical study and practical experience.
Students can benefit a lot from courses like machine design and charting,
their spatial imagination ability improved, their groundwork for further
professional curriculum study and future career practice well done.
Generally, students are schedules to learn mechanical design and drawing
course when they are freshmen. These courses serve as a connecting link
between the preceding and the following in cultivating students’
professional ability. The teaching quality concerns the grasp of subsequent
professional knowledge directly and even influences students’ curriculum
design and diploma project. Moreover, mechanical design and drafting
courses also have a strong application in future career. These courses
mainly base on orthographic principles and adopt 2D figures to express
3D objects. Students need to have a strong spatial analysis capacities and
imagination abilities, and it is difficult to learn these courses are short of
mechanical parts understanding and adequate space imagination. The very
reason why these courses are difficult to students is that they are required
to transfer between 3D objects and 2D pictures in traditional machine
design and charting courses [2]. It would benefit a lot if there is a bridge
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to combine the design and manufacture process perfectly; take 3D
software into mechanical design courses for teaching. Using computer
directly for solid modeling can establish a visual link and get rid of the
conversion between the 2D figures and 3D objects. Thus, it will enhance
students’ understanding about figures and inspire the enthusiasm of
students.
Part design
The Part Design Workbench is utilized to make Solid geometry utilizing
a Feature based methodology. As a rule the highlights are delivered from
portrays made in the Sketcher Workbench. The particular tree contains all
the highlights made alongside the sketch used to characterize them. All
the Solid highlights are contained inside a hub called a Part Body. They
likewise contain wireframe draws that are utilized to make the highlights.
As you make highlights they are added to the tree arranged by creation.
Part bodies can be added to the Specification Tree by choosing Body from
the Insert drop down menu when in the Part Design Workbench. The Part
body would then be able to be renamed by altering its properties.

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1. TOP PART

2. THERADE PART

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 3.

3. SPRING PART

4. GEAR PART
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5. ASSEMBLY

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ANSYS SIMULATION:
Introduction

ANSYS is a building reenactment programming supplier established by

programming engineer John Swanson. It creates universally useful limited
component investigation and computational liquid elements
programming. While ANSYS has built up a scope of PC supported
building (CAE) items, it is maybe most popular for its ANSYS
Mechanical and ANSYS Multi-material science items.
ANSYS Mechanical and ANSYS Multi-material science programming
are non-exportable investigation instruments joining pre-handling
(geometry creation, fitting), solver and post-Processing modules in a
graphical UI. These are universally useful limited component
demonstrating bundles for numerically taking care of mechanical issues,
including static/unique auxiliary investigation (both direct and non-
straight), heat move and liquid issues, just as acoustic and electro-
attractive issues.
ANSYS Mechanical innovation joins both basic and material non-
linearity. ANSYS Multi-material science programming incorporates
solvers for warm, basic, CFD, electro-attractive, and acoustics and can in
some cases couple these different material science together so as to
address multidisciplinary applications. ANSYS programming can
likewise be utilized in structural designing, electrical building, material
science and science.

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Ansys workbench Analysis

The ANSYS Workbench stage is the system whereupon the business'

broadest and most profound set-up of cutting edge building reproduction
innovation is fabricated. A creative venture schematic view integrates the
whole re-enactment process, managing the client through even complex
transcendentalism investigations with intuitive straightforwardness. With
bidirectional CAD network, amazing exceptionally robotized fitting, a
task level update instrument, unavoidable boundary the board and
coordinated improvement devices, the ANSYS Workbench stage conveys
uncommon efficiency, empowering Simulation Driven Product
Development. The Workbench environment allows you to solve much
more complex analyses, including:
1. Multi-part assemblies.
2. 3-D solid elements, shell elements, and shell solid assemblies.
3. Nonlinear contact with or without friction.
4. Small-displacement and large-displacement static analyses.
5. Modal, harmonic, and Eigen value buckling analyses.
6. Steady-state thermal analysis, including temperature-dependent
material properties and thermal contact.

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 6. MESHED MODEL

Static Structural Analysis for Shock Absorber using Chrome

Vanadium ASTM 231(High Carbon Steel) as Spring Steel:

• Bike Weight with two Person (125kg+150kg)= 275kg=2696.82 N

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1. Equivalent stress= -2696.82 N
(Chrome Vanadium)

2. Total deformation= -2696.82 N

(Chrome Vanadium)
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Static Structural Analysis for Shock Absorber using Hard Drawn
ASTM A227 (Alloy Steel) as Spring Steel:

• Bike Weight with two Person (125kg+150kg)=275kg =2696.82 N

1. Equivalent stress = - 2696.82 N

(Hard Drawn)

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 2. Total deformation= -2696.82 N
(Hard Drawn)

Static Structural Analysis for Shock Absorber using Structural Steel

as Spring Steel:
• Bike Weight with two Person (125kg+150kg)=275kg =2696.82 N

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1. Equivalent stress = - 2696.82 N

2. Total deformation= -2696.82 N

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 RESULT AND DISCUSSION:
MATERIALS STRESS(Pa) DEFORMATION

MAXIMUM MINIMUM MAXIMUM

High carbon 1.0802*10^7 -1.3537*10^7 1.0187*10^-5

steel
Structural steel 1.0786*10^-5 0 1.0786*10^-5

Alloy steel 1.0272*10 0 1.0272*10^-5

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CONCLUSION:

• In this project a shock absorber is designed and a 3D model is

created using SOLIDWORKS.
• Structural analysis was done on the shock absorber by varying
material for chrome vanadium and hard drawn steel at different
loads.
• Total deformation and Equivalent stress are calculated.
• The equivalent stresses and total deformation for chrome vanadium
are very low as compared to hard drawn steel.
• Conclude that as per our analysis using material chrome vanadium
for spring is best and also design is safe.

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REFERENCES:
[1]. V. P. Patil. S. S. Gawade. “Experimental Analysis of An Electrically
Powered Active Hybrid Suspension (EPAHS) For
Vehicle” International Journal of Engineering Research & Technology
(IJERT), July –2013 Vol. 2 Issue 7
[2]. Yongjie Lu, Shaohua Li and Na Chen “Research on Damping
Characteristics of Shock Absorber for Heavy Vehicle” Research
Journal of Applied Sciences, Engineering and Technology 5(3): 842-
847,2013 ISSN: 2040-7459; E-ISSN: 2040-7467
[3]. Pinjarla.Poornamohan1, Lakshmana Kishore.T “Design And Analysis
Of A Shock Absorber” International Journal of Engineering
Research & Technology(IJERT) Dec – 2012, Volume: 1 Issue: 4 pp. 578
–592
[4]. Priyanka Ghate, Dr. Shankapal S. R., Monish Gowda M. H. “Failure
Investigation of a Freight Locomotive Suspension Spring and
Redesign of the spring for Durability and ride index”. SASTECH Journal
Volume11, Issue 2, Sep – 2012,
[5]. Saurabh Singh, “Optimization of Design of Helical Coil Suspension
System by Combination of Conventional Steel and Composite
Material in Regular Vehicle”International Journal of Applied Engineering
Research,ISSN 0973-4562 Vol.7 No.11 (2012)
[6]. D. Abdul Budan, T.S. Manjunatha, “Investigation on the Feasibility
of Composite Coil Spring for Automotive Applications” World
Academy of Science,Engineering and Technology 46 [2010].

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