Design and Analysis of Helical Compression Spring for Shock Absorber
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The document discusses the design and analysis of a helical compression spring for a shock absorber. It analyzes springs made of phosphor bronze, spring brass, and carbon steel. The analysis found that phosphor bronze had the highest deformation and energy storage capacity, making it best suited to absorb shocks compared to the other materials. Finite element analysis in ANSYS was used to simulate loads on the different spring designs and materials. The analysis concluded that phosphor bronze is the best material for the helical compression spring based on its shock absorbing capabilities.
![REFERENCE
[1] Akshat Jain, Sheelam Misra, Arun Jindal, Prateek Lakhian, 2017,
“Structural Analysis of Compression Helical Spring Used in Suspension
System”, American Institute of Physics, Vol.3.
[2] Atul.M, Pungal, Prof. Bhosale.K.C, 2018, “Comparative analysis of two
wheeler suspension helical compression spring for steel and composite
material at different loading conditions”, International Research Journal of
Engineering and Technology, Vol.5.
[3] Chavhan.G.R, Burande.S.W, Dhole.L.P, 2014, “Analysis of shock absorber
using different material of spring” International Journal of Advanced
Engineering Technology, Vol .8.
[4] Khurmi R.S and Gupta J.K, 2005, “Theory of machines” Fourteen edition,
S.Chand Publication, pp. 907-940.
[5] Michael F.Ashby, 2011, “Material selection in mechanical design” Fourth
edition, Elsevier ltd, pp. 31-55.
[6] Pawar.H.B, Desale.D.D, 2018, “optimization of three wheeler front
suspension coil spring” ELSEVIER , Vol.7.](https://image.slidesharecdn.com/finalyearproject-190803143319/85/Design-and-Analysis-of-Helical-Compression-Spring-for-Shock-Absorber-37-320.jpg)
![REFERENCE(Cont.)
[7] Prince Jerome Christopher.J, Pavendhan.R, 2012, “Design and Analysis of
Two Wheeler Shock Absorber Coil Spring” International Journal of
Modern Engineering Research, Vol.12.
[8] Robert L. Norton, 2010, “Machine design an integrated approach” Fourth
edition, Pearson publication, pp. 785-806.
[9] Singh Pankaj, Amilkanthwar Rushikesh, Walli Sanket, Jasoliya Viraj, Patel
Kaushal, 2017, “Design and analysis of helical compression spring used in
suspension system by finite element analysis method” International
Research Journal of Engineering and Technology, Vol.6.
[10] Vijayeshwar B.V, Preetham B.M, Bhaskar U, 2017, “Design and Static
Analysis of Helical Suspension Spring with Different Materials”,
International Advanced Research Journal in Science, Engineering and
Technology, Vol.4.](https://image.slidesharecdn.com/finalyearproject-190803143319/85/Design-and-Analysis-of-Helical-Compression-Spring-for-Shock-Absorber-38-320.jpg)
Design and Analysis of Helical Compression Spring for Shock Absorber
- 1. DESIGN AND ANALYSIS OF HELICAL COMPRESSION SPRING FOR SHOCK ABSORBER Presented By P.NAVEEN S.SANGARGANESH R.SRINIVASAN K. SUKUMAR Under the Supervision Of Prof. A. PERAMANAN M.E.,(Ph.D) Department of Mechanical Engineering Jai Shriram Engineering College, Tirupur.
- 2. ABSTRACT The helical compression spring is used in a shock absorber to absorb the shock and vibrations during tracking. The spring is made up of elastic material to regain its original shape. The spring goes down below its normal height when the weight of the vehicle pushes the spring down. The compressed spring rebound to its normal dimension or original length when the load is removed. For this project the materials of Phosphor Bronze and Spring Brass were taken for consideration. The Phosphor Bronze and Spring Brass are a non-ferrous copper base alloy material which having a high fatigue resistance, temperature resistance and corrosion resistance. The analysis was done by considering bike loads based on the number of persons seated on bike. As a result, this project highlights static and dynamic behaviours of a helical compression spring. Finally compare this analysis result to ferrous material (Carbon Steel) to find which one is better for make a helical compression spring ferrous material or non-ferrous material.
- 3. CHAPTER-1 INTRODUCTION • Helical compression springs are used widely all over the world. It has different type of applications in different areas. According to that the design considerations are to be made. The chapter further discusses about basic phenomenon like stability of spring, surge in spring, spring relaxation, fatigue loading, strain energy. and basic design procedure of the helical compression springs.
- 4. SPRINGS • A spring is defined as an elastic machine element, which deflects under the action of the load and returns to its original shape when the load is removed. • Springs are used to absorb shocks and vibrations. • Springs are used to measure force. • Springs are used to store energy.
- 5. SPRING MATERIALS • The ideal spring material would have a high ultimate strength, high yield point, and low modulus of elasticity in order to provide maximum energy storage. Carbon Steel Alloy Steel a) Chrome Vanadium b) Chrome Silicon Stainless Steel
- 6. SPRING MATERIALS (Cont.) Copper Base Alloys a) Phosphor Bronze b) Silicon Bronze c) Beryllium Copper d) Spring Brass Nickel Base Alloys a) Inconel b) Monel
- 7. CHAPTER-2 LITERATURE REVIEW The helical compression spring used in suspension system or shock absorbers and linkages which are used to connect vehicle and allow relative motion between them, spring is an important element in suspension system. The suspension system reduces the amplitude of disturbances by absorbing and handling shock impulses and dissipating kinetic energy generated due to improper road condition. The project work is based on CATIA and ANSYS. The statistical structural analysis would be done by finite element analysis method in ANSYS for different spring materials and wire diameter of spring. The ANSYS is done by considering bike mass, loads, and number of persons seated on bike.
- 8. CHAPTER-3 PROBLEM IDENTIFICATION • In the helical compression spring, the material of carbon steel is mostly used because it having a high tensile and yield strength, despite their high modulus of elasticity. The material of carbon steel having a high modulus of rigidity so the deflection is low for carbon steel. If the deflection is less the energy storing capacity is low. • So we choose the phosphor bronze and spring brass which have a high tensile and yield strength than carbon steel. The deformation is higher because of low modulus of rigidity. These materials phosphor bronze and spring brass are non-ferrous so temperature resistance and corrosion resistance are more than carbon steel.
- 9. METHODOLOGY Conclusion Result and discussion Analysis(ANSYS) Modelling(CATIA) Design calculation Selection of material Feasibility study Problem identification
- 10. CHEMICAL COMPOSITION Phosphor bronze Tin 4.2to 5.8% Phosphorous 0.03to0.35% Iron(Max) 0.10% Lead 0.05% Zinc 0.30% Copper+ tin Phosphorous 95% Carbon Steel Carbon 0.03 to 1.25% Iron 80 to 90% Manganese 0.20to 16% Phosphorous 0.040% Silicon 0.50% Sulfur 0.005%
- 11. CHEMICAL COMPOSITION (Cont.) Spring Brass Copper 68.5-71.5% Iron 0.05(Max)% Lead 0.07(Max)% Zinc Remainder(Approxim ately 30%)
- 12. MECHANICAL PROPERTIES Phosphor Bronze Modulus of elasticity 103400 Mpa Modulus of rigidity 41370 Mpa Tensile strength 550 Mpa Yield strength 450 Mpa Hardness Rockwell 85 Carbon Steel Modulus of elasticity 193000 Mpa Modulus of rigidity 80000 Mpa Tensile strength 540 Mpa Tensile strength, yield 415 Mpa Hardness Rockwell 46
- 13. Spring Brass Modulus of elasticity 103400 Mpa Modulus of rigidity 34500 Mpa Tensile strength 690 Yield strength 480 Hardness Rockwell 90
- 14. SPECIFICATIONS OF HELICAL SPRING • Spring material : Carbon Steel • Wire diameter, d = 8 mm • Spring index, C = 6 • Mean coil diameter, D = 48 mm • Number of coils, N = 15 • Loads Applied = I. 830 II. 1565 N III. 2300 N • Free length = 243.12 mm • Pitch = 15.195 mm
- 15. SPECIFICATIONS OF HELICAL SPRING(Cont…) Load (N) Material Deflection (mm) Stiffness (N/mm) Shear stress (Mpa) Energy storage (N-mm) Carbon steel 33.62 24.68 13952.3 830 Phosphor bronze 65.00 12.76 247.86 26975.0 Spring brass 63.94 12.98 26535.0 Carbon steel 63.38 24.68 49594.85 1565 Phosphor bronze 122.45 12.76 467.02 95817.12 Spring brass 119.93 12.98 93845.2 Carbon steel 93.150 24.68 107122.5 2300 Phosphor bronze 180.23 12.76 686.35 207264.5 Spring brass 177.53 12.98 204159.5
- 16. DESIGN OF HELICAL SPRING
- 17. DRAFTING OF HELICAL SPRING
- 18. ANALYSIS OF HELICAL SPRING
- 20. Total deformation • Carbon Steel • 1565 N
- 21. Shear stress • Carbon steel • 1565 N
- 22. Total deformation • Phosphor bronze • 1565 N
- 23. Shear stress • Phosphor bronze • 1565 N
- 24. Total deformation • Spring Brass • 1565N
- 25. Shear stress • Spring brass • 1565N
- 26. Load(N) Material Deformation(mm) Shear stress(Mpa) Theoretical ANSYS Theoretical ANSYS Carbon Steel 33.620 31.754 240.76 830 Phosphor Bronze 65.000 66.266 247.86 239.26 Spring Brass 63.940 60.680 240.05 Carbon Steel 63.380 59.874 453.96 1565 Phosphor Bronze 122.45 124.95 467.02 451.13 Spring Brass 119.87 114.42 457.62 Carbon Steel 93.150 87.993 667.16 2300 Phosphor Bronze 180.23 183.63 686.35 663.00 Spring Brass 176.94 168.15 665.19
- 27. 0 100 200 300 400 500 600 700 800 Carbon Steel Phosphor Bronze Spring Brass Carbon Steel Phosphor Bronze Spring Brass Carbon Steel Phosphor Bronze Spring Brass 830 830 830 1565 1565 1565 2300 2300 2300 Chart Title Deformation(mm) Theoretical Deformation(mm) ANSYS Shear stress(Mpa) Theoretical Shear stress(Mpa) ANSYS
- 28. Total deformation • Carbon Steel • 1565N
- 29. Shear stress • Carbon steel • 1565 N
- 30. Total deformation • Phosphor Bronze • 1565 N
- 31. Shear stress • Phosphor Bronze • 1565 N
- 32. Total deformation • Spring brass • 1565N
- 33. Shear stress • Spring brass • 1565N
- 34. Load(N) Material Frequency (Hz) Deformation(mm) Shear stress(Mpa) Theoretical ANSYS Theoretical ANSYS Carbon Steel 2.718 33.620 32.123 243.51 830 Phosphor Bronze 1.950 65.000 67.147 247.86 242.52 Spring Brass 1.970 63.940 61.415 242.99 Carbon Steel 1.980 63.380 60.232 456.66 1565 Phosphor Bronze 1.420 122.45 125.08 467.02 454.32 Spring Brass 1.438 119.87 115.13 455.52 Carbon Steel 1.630 93.150 88.346 669.83 2300 Phosphor Bronze 1.170 180.23 184.47 686.35 666.16 Spring Brass 1.184 176.94 168.86 668.06
- 35. 0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 360 380 400 420 440 460 480 500 520 540 560 580 600 620 640 660 680 700 720 740 Carbon Steel Phosphor Bronze Spring Brass Carbon Steel Phosphor Bronze Spring Brass Carbon Steel Phosphor Bronze Spring Brass 830 830 830 1565 1565 1565 2300 2300 2300 Chart Title Frequency (Hz) Deformation(mm) Theoretical Deformation(mm) ANSYS Shear stress(Mpa) Theoretical Shear stress(Mpa) ANSYS
- 36. CONCLUSION In this project we have designed a helical compression spring. Structural and harmonic analysis of the helical springs of various materials are analyzed by ANSYS software. By comparing these results, the total deformation of phosphor bronze material is more than the other materials (carbon steel and spring brass) hence shock absorbing capacity of phosphor bronze is more than carbon steel and spring brass. The stiffness of phosphor bronze is less than the carbon steel and spring brass hence it can deflect a high load. So finally conclude that as per analysis the Phosphor bronze is best.
- 37. REFERENCE [1] Akshat Jain, Sheelam Misra, Arun Jindal, Prateek Lakhian, 2017, “Structural Analysis of Compression Helical Spring Used in Suspension System”, American Institute of Physics, Vol.3. [2] Atul.M, Pungal, Prof. Bhosale.K.C, 2018, “Comparative analysis of two wheeler suspension helical compression spring for steel and composite material at different loading conditions”, International Research Journal of Engineering and Technology, Vol.5. [3] Chavhan.G.R, Burande.S.W, Dhole.L.P, 2014, “Analysis of shock absorber using different material of spring” International Journal of Advanced Engineering Technology, Vol .8. [4] Khurmi R.S and Gupta J.K, 2005, “Theory of machines” Fourteen edition, S.Chand Publication, pp. 907-940. [5] Michael F.Ashby, 2011, “Material selection in mechanical design” Fourth edition, Elsevier ltd, pp. 31-55. [6] Pawar.H.B, Desale.D.D, 2018, “optimization of three wheeler front suspension coil spring” ELSEVIER , Vol.7.
- 38. REFERENCE(Cont.) [7] Prince Jerome Christopher.J, Pavendhan.R, 2012, “Design and Analysis of Two Wheeler Shock Absorber Coil Spring” International Journal of Modern Engineering Research, Vol.12. [8] Robert L. Norton, 2010, “Machine design an integrated approach” Fourth edition, Pearson publication, pp. 785-806. [9] Singh Pankaj, Amilkanthwar Rushikesh, Walli Sanket, Jasoliya Viraj, Patel Kaushal, 2017, “Design and analysis of helical compression spring used in suspension system by finite element analysis method” International Research Journal of Engineering and Technology, Vol.6. [10] Vijayeshwar B.V, Preetham B.M, Bhaskar U, 2017, “Design and Static Analysis of Helical Suspension Spring with Different Materials”, International Advanced Research Journal in Science, Engineering and Technology, Vol.4.
- 39. THANK YOU