Design and Analysis of A Shock Absorber

IJRET: International Journal of Research in Engineering and Technology ISSN: 2319-1163
DESIGN AND ANALYSIS OF A SHOCK ABSORBER
Pinjarla.Poornamohan1, Lakshmana Kishore.T2

1
M.Tech (student), 2M.Tech (Associate Professor), Mechanical Department, GIET, Andhra Pradesh, India
poornamohan_mech@yahoo.com, tlkishore.giet@gmail.com
Abstract
A suspension system or shock absorber is a mechanical device designed to smooth out or damp shock impulse, and dissipate kinetic
energy. The shock absorbers duty is to absorb or dissipate energy. In a vehicle, it reduces the effect of traveling over rough ground,
leading to improved ride quality, and increase in comfort due to substantially reduced amplitude of disturbances. When a vehicle is
traveling on a level road and the wheels strike a bump, the spring is compressed quickly. The compressed spring will attempt to return
to its normal loaded length and, in so doing, will rebound past its normal height, causing the body to be lifted. The weight of the
vehicle will then push the spring down below its normal loaded height. This, in turn, causes the spring to rebound again. This
bouncing process is repeated over and over, a little less each time, until the up-and-down movement finally stops. If bouncing is
allowed to go uncontrolled, it will not only cause an uncomfortable ride but will make handling of the vehicle very difficult. The
design of spring in suspension system is very important. In this project a shock absorber is designed and a 3D model is created using
Pro/Engineer. The model is also changed by changing the thickness of the spring. Structural analysis and modal analysis are done on
the shock absorber by varying material for spring, Spring Steel and Beryllium Copper. The analysis is done by considering loads, bike
weight, single person and 2 persons. Structural analysis is done to validate the strength and modal analysis is done to determine the
displacements for different frequencies for number of modes. Comparison is done for two materials to verify best material for spring
in Shock absorber. Modeling is done in Pro/ENGINEER and analysis is done in ANSYS. Pro/ENGINEER is the standard in 3D
product design, featuring industry-leading productivity tools that promote best practices in design.ANSYS is general-purpose finite
element analysis (FEA) software package. Finite Element Analysis is a numerical method of deconstructing a complex system into
very small pieces (of user-designated size) called elements.
Index Terms: damp shock, kinetic energy, Pro/Engineer, and ANSYS, shock absorber
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1. INRODUCTION 1.3 Applications

A shock absorber or damper is a mechanical device designed Shock absorbers are an important part of automobile and
to smooth out or damp shock impulse, and dissipate kinetic motorcycle suspensions, aircraft landing gear, and the supports
energy. for many industrial machines. Large shock absorbers have also
been used in structural engineering to reduce the susceptibility
1.1 Description of structures to earthquake damage and resonance. A
transverse mounted shock absorber, called a yaw damper,
Pneumatic and hydraulic shock absorbers commonly take the helps keep railcars from swaying excessively from side to side
form of a cylinder with a sliding piston inside. The cylinder is and are important in passenger railroads, commuter rail and
filled with a fluid (such as hydraulic fluid) or air. This fluid- rapid transit systems because they prevent railcars from
filled piston/cylinder combination is a dashpot. damaging station platforms. The success of passive damping
technologies in suppressing vibration amplitudes could be
1.2 Explanation ascertained with the fact that it has a market size of around $
The shock absorbers duty is to absorb or dissipate energy. One 4.5 billion.
design consideration, when designing or choosing a shock
absorber, is where that energy will go. In most dashpots,
energy is converted to heat inside the viscous fluid. In
hydraulic cylinders, the hydraulic fluid will heat up, while in
air cylinders, the hot air is usually exhausted to the
atmosphere. In other types of dashpots, such as
electromagnetic ones, the dissipated energy can be stored and
used later. In general terms, shock absorbers help cushion cars
on uneven roads.
Fig 1.1:- Rear shock absorber and spring of a BMW R75/5
motorcycle
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Volume: 01 Issue: 04 | Dec-2012, Available @ http://www.ijret.org 578
1.4 Vehicle suspension simple hand tools. A disadvantage is that the

damping force tends not to increase with the speed of
In a vehicle, it reduces the effect of traveling over rough

the vertical motion.
ground, leading to improved ride quality, and increase in Solid state, tapered chain shock absorbers, using one
comfort due to substantially reduced amplitude of or more tapered, axial alignment(s) of granular
disturbances. Without shock absorbers, the vehicle would have spheres, typically made of metals such as nitinol, in a
a bouncing ride, as energy is stored in the spring and then

casing. [1],[2]
released to the vehicle, possibly exceeding the allowed range Fluid friction, for example the flow of fluid through a
of suspension movement. Control of excessive suspension narrow orifice (hydraulics), constitutes the vast
movement without shock absorption requires stiffer (higher majority of automotive shock absorbers. An
rate) springs, which would in turn give a harsh ride. Shock advantage of this type is that using special internal
absorbers allow the use of soft (lower rate) springs while valving the absorber may be made relatively soft to
controlling the rate of suspension movement in response to compression (allowing a soft response to a bump)
bumps. They also, along with hysteresis in the tire itself, damp and relatively stiff to extension, controlling "jounce",
the motion of the unspring weight up and down on the which is the vehicle response to energy stored in the
springiness of the tire. Since the tire is not as soft as the springs; similarly, a series of valves controlled by
springs, effective wheel bounce damping may require stiffer springs can change the degree of stiffness according
shocks than would be ideal for the vehicle motion alone. to the velocity of the impact or rebound. Specialized
Spring-based shock absorbers commonly use coil springs or shock absorbers for racing purposes may allow the
leaf springs, though torsion bars can be used in tensional front end of a dragster to rise with minimal resistance
shocks as well. Ideal springs alone, however, are not shock under acceleration, then strongly resist letting it
absorbers as springs only store and do not dissipate or absorb settle, thereby maintaining a desirable rearward
energy. Vehicles typically employ springs and torsion bars as weight distribution for enhanced traction. Some
well as hydraulic shock absorbers. In this combination, "shock shock absorbers allow tuning of the ride via control
absorber" is reserved specifically for the hydraulic piston that of the valve by a manual adjustment provided at the
absorbs and dissipates vibration. shock absorber. In more expensive vehicles the
valves may be remotely adjustable, offering the
1.5 Structures driver control of the ride at will while the vehicle is
Applied to a structure such as a building or bridge it may be operated. The ultimate control is provided by
part of a seismic retrofit or as part of new, earthquake resistant dynamic valve control via computer in response to
construction. In this application it allows yet restrains motion sensors, giving both a smooth ride and a firm
and absorbs resonant energy, which can cause excessive suspension when needed. Many shock absorbers
motion and eventual structural failure. contain compressed nitrogen, to reduce the tendency
for the oil to foam under heavy use. Foaming
1.6Types of shock absorbers temporarily reduces the damping ability of the unit.
In very heavy duty units used for racing and/or off-
There are several commonly-used approaches to shock road use, there may even be a secondary cylinder
 Hysteresis of structural material, for example the

absorption: connected to the shock absorber to act as a reservoir
for the oil and pressurized gas. Another variation is
compression of rubber disks, stretching of rubber the Magneto rheological damper which changes its
bands and cords, bending of steelsprings, or twisting

fluid characteristics through an electromagnet.
of torsion bars. Hysteresis is the tendency for Compression of a gas, for example pneumatic shock
otherwise elastic materials to rebound with less force absorbers, which can act like springs as the air
than was required to deform them. Simple vehicles pressure is building to resist the force on it. Once the
with no separate shock absorbers are damped, to air pressure reaches the necessary maximum, air
some extent, by the hysteresis of their springs and dashpots will act like hydraulic dashpots. In aircraft
 Dry friction as used in wheel brakes, by using disks

frames. landing gear air dashpots may be combined with
hydraulic damping to reduce bounce. Such struts are
(classically made of leather) at the pivot of a lever,

called oleo struts (combining oil and air) [3].
with friction forced by springs. Used in early Magnetic effects. Eddy current dampers are dashpots
automobiles such as the Ford Model T, up through that are constructed out of a large magnet inside of a
some British cars of the 1940s. Although now

non-magnetic, electrically conductive tube.
considered obsolete, an advantage of this system is its Inertial resistance to acceleration, for example prior
mechanical simplicity; the degree of damping can be to 1966 [4] the Citroën 2CV had shock absorbers that
easily adjusted by tightening or loosening the screw damp wheel bounce with no external moving parts.
clamping the disks, and it can be easily rebuilt with These consisted of a spring-mounted 3.5 kg (7.75 lb)
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iron weight inside a vertical cylinder [5] and are general in nature provided to show the benefits of
similar to, yet much smaller than versions of the using shock absorbers. For more detailed information

tuned mass dampers used on tall buildings - links are provided to shock absorber suppliers.
Composite hydro-pneumatic devices which combine
in a single device spring action, shock absorption, 1.7 Shock Absorber types
and often also ride-height control, as in some models
There are a number of different methods of converting an

of the Citroën automobile.
 Metal Spring
Conventional shock absorbers combined with impact /collision into relatively smooth cushioned contact..
 Rubber Buffer
composite pneumatic springs with which allow ride
 Hydraulic Dashpot
height adjustment or even ride height control, seen in
 Collapsing safety Shock Absorbers
some large trucks and luxury sedans such as certain
 Pneumatic Cylinders
Lincoln and most Land Rover automobiles. Ride
 Self compensating Hydraulic
height control is especially desirable in highway
vehicles intended for occasional rough road use, as a
means of improving handling and reducing
aerodynamic drag by lowering the vehicle when 1.7.1 Metal springs

operating on improved high speed roads. Simply locating metal springs to absorb the impact loads are a
the effect of a shock absorber at high (sound) low cost method of reducing the collision speed and reducing
frequencies is usually limited by using a the shock loading. They are able to operate in very arduous
compressible gas as the working fluid and/or conditions under a wide range of temperatures. These devices

mounting it with rubber bushings. have high stopping forces at end of stroke. Metal springs store
The detailed analysis of shock absorber/isolation energy rather than dissipating it. If metal sprint type shock
systems is very complicated and involves assessment absorbers are used then measures should be provided to limit
of the dynamic response of the equipment to different Oscillations. Metal springs are often used with viscous
types of activating energy inputs. The notes below dampers.
relate only to illustrating the benefits of using shock
absorbers to reduce the forces experienced by There are a number of different types of metal springs
equipment to impacts. The more complicated including helical springs, bevel washers(cone-springs), leaf
scenarios involving systems continuously operating springs, ring springs, mesh springs etc etc. Each spring type
and withstanding sudden changes of loading and has its own operating characteristics.
acceleration e.g., car suspension systems and aircraft
landing gear, are outside of the scope of this work. 1.7.2 Elastomatic shock observers
Moving objects have kinetic energy related to their
velocity and their mass. If the velocity of an object is These are low cost options for reducing the collision speed
significantly changed in a short time span e.g. it and reducing the shock loading and providing system
impacts on a stationary body, then high forces result. damping. They are conveniently moulded to suitable shapes.
These forces can be useful e.g., a forging press using These devices have high stopping forces at end of stroke with
the kinetic energy to form metal. However real life significant internal damping. Elastomeric dampers are very
impact forces (shock loads) are generally very widely used because of the associated advantages of low cost
destructive and are avoided. Kinetic energy increases and mouldability together with performance benefits. The
in a direct ratio to the mass and to the velocity inherent damping of elastomers is useful in preventing
excessive vibration amplitude at resonance – much reduced

squared.
The heavier the object or the faster it travels, the compared to metal springs. However elastomeric based shock
more energy it has. Methods of energy absorption absorbers are limited in being affected by high and low
include rubber buffers, metal springs, air springs, and temperatures. And are subject to chemical attack. Silicone
hydraulic shock absorbers. When the systems have to rubber is able to provide reasonable mechanical properties
continuously operate under the influence of shock between temperatures of -50O to +180O deg. C- most other
loads the shock isolation system generally includes elastomer has inferior temperature tolerance.
spring-dashpot isolation systems. For simple shock
absorber applications required to mitigate the effect 1.7.3 Hydraulic Dashpot
of a single events then viscous dampers which
dissipate the energy, as heat rise of a fluid, are often This type of shock absorber is based on a simple hydraulic
preferred. In normal everyday life simple examples cylinder. As the piston rod is moved hydraulic fluid is forced
of shock absorber systems include crash helmets, through an orifice which restricts flow and consequently
steel toe caps in industrial boots, collapsible bumpers provides a controlled resistance to movement of the piston
on cars, motor way barriers. The notes below are rod. With only one metering orifice the moving load is
abruptly slowed down at the start of the stroke. The braking
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force rises to a very high peak at the start of the stroke and Weight of bike + persons = 275Kgs
then falls away rapidly. On completion of the stroke the Rear suspension = 65%
system is stable - the energy being dissipated in the hydraulic 65% of 275 = 165Kgs
fluid as heat. This type of shock absorbers are provided with Considering dynamic loads it will be double
Springs sufficient to return the actuator to its initial position W = 330Kgs = 3234N
after the impacting load is removed. For single shock absorber weight = w/2= 1617N = W
We Know that, compression of spring (δ) = × × /×
1.7.4 Collapsing Safety Shock Absorbers C = spring index = = = 7.75 = 8
(δ) = × × × /× = 282.698
These are single use units which are generally specially Solid length, Ls=n1×d=18×8=144
designed for specific duties. They are designed such that at Free length of spring,
impact they collapse and the impact energy is absorbed as the Lf = solid length+maximum compression + clearance between
materials distort in their inelastic/yield range. They therefore adjustable coils
are more compact compared to devices based on deflections = + + 0.15 = 144 + 282.698 + 0.15 × 282.698 = 469.102
within their elastic range. Spring rate, K = = . = 5.719
Pitch of coil, P = = . = 26
1.7.5 Air (Pneumatic) spring Stresses in helical springs: maximum shear stress induced in
These devices use air as the resilient medium. Air has a high the wire
energy storage capacity compared to metal or elastomer τ = K×
materials. For duties with high loads and deflections the air K=+.=×
spring is generally far more compact that the equivalent metal × + . = 0.97
or elastomer device. Due to the compressibility of air these τ = K× = 0.97 × × ×
have a sharply rising force characteristic towards the end of × = 499.519
the stroke. The majority of the energy is absorbed near the end Buckling of compression springs, = × ×
of the stroke.The force on an air cylinder buffer is determined Values of buckling factor KB= 7.5
by the relation PVn=constant. Air springs require more K = 0.05 (for hinged and spring)
maintenance than meal or elastomer based springs and the The buckling factor for the hinged end and built-in end springs
temperature range is restricted compared to metal springs. Wcr=5.719×0.05×469.102=134.139N
1.7.6 Self compensating Hydraulic 2. INTRODUCTION TO PRO/ENGINEER

These devices are similar to the hydraulic dashpot type except Pro/ENGINEER is a feature based, parametric solid modeling
that a number of orifices are provided allowing different program. As such, it's use is significantly different from
degrees of restriction throughout the stroke. These devices are conventional drafting programs. In conventional drafting
engineered to bring the moving load is smoothly and gently to (either manual or computer assisted), various views of a part
rest by a constant resisting force throughout the entire shock are created in an attempt to describe the geometry. Each view
absorber stroke. The load is decelerated with the lowest incorporates aspects of various features (surfaces, cuts, radii,
possible force in the shortest possible time eliminating holes, protrusions) but the features are not individually
damaging force peaks and shock damage to machines and defined. In feature based modeling, each feature is
equipment. These type of shock absorbers are provided with individually described then integrated into the part. The other
springs sufficient to return the actuator to its initial position significant aspect of conventional drafting is that the part
after the impacting load is removed. geometry is defined by the drawing. If it is desired to change
the size, shape, or location of a feature, the physical lines on
1.8 Design Calculations for Helical springs for Shock the drawing must be changed (in each affected view) then
associated dimensions are updated. When using parametric
absorbers modeling, the features are driven by the dimensions
(parameters). To modify the diameter of a hole, the hole
Material: Steel(modulus of rigidity) G = 41000 diameter parameter value is changed. This automatically
Mean diameter of a coil D=62mm modifies the feature wherever it occurs – drawing views,
Diameter of wire d = 8mm assemblies, etc. Another unique attribute of Pro/ENGINEER
Total no of coils n1= 18 is that it is a solid modeling program. The design procedure is
Height h = 220mm to create a model, view it, assemble parts as required, then
Outer diameter of spring coil D0 = D +d =70mm generate any drawings which are required. It should be noted
No of active turns n= 14 that for many uses of Pro/E, complete drawings are never
Weight of bike = 125kgs created. A typical design cycle for a molded plastic part might
Let weight of 1 person = 75Kgs consist of the creation of a solid model, export of an SLA file
Weight of 2 persons = 75×2=150Kgs to a rapid prototyping system (stereolithography, etc.), use of
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the SLA part in hands-on verification of fit, form, and 3. MODEL OF SHOCK ABSORBER
function, and then export of an IGES file to the molder or
toolmaker. A toolmaker will then use the IGES file to program 3.1 PARTS OF SHOCK ABSORBER
the NC machines which will directly create the mold for the 3.1.1 BOTTOM PART
parts. In many such design cycles, the only print created will
be an inspection drawing with critical and envelope
dimensions shown.
2.1 Summary of capabilities

Like any software it is continually being developed to include
new functionality. The details below aim to outline the scope
of capabilities to give an overview rather than giving specific
details on the individual functionality of the product.
Pro/Engineer is a software application within the
CAID/CAD/CAM/CAE category, along with other similar
products currently on the market. Pro/Engineer is a
parametric, feature-based modeling architecture incorporated
into a single database philosophy with advanced rule-based
design capabilities. The capabilities of the product can be split
into the three main heading of Engineering Design, Analysis
and Manufacturing. This data is then documented in a
standard 2D production drawing or the 3D drawing standard
ASME Y14.41-2003.
Fig 3.1:- Bottom part
2.2 Engineering Design
Pro/Engineer offers a range of tools to enable the generation 3.1.2 TOP PART
of a complete digital representation of the product being
designed. In addition to the general geometry tools there is
also the ability to generate geometry of other integrated design
disciplines such as industrial and standard pipe work and
complete wiring definitions. Tools are also available to
support collaborative development. A number of concept
design tools that provide up-front Industrial Design concepts
can then be used in the downstream process of engineering the
product. These range from conceptual Industrial design
sketches, reverse engineering with point cloud data and
comprehensive freeform surface tools.
2.3 DIFFERENT MODULES IN PRO/ENGINEER


PART DESIGN

ASSEMBLY

DRAWING
SHEETMETAL
Fig 3.2:- Top part
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3.1.3 HELICAL SPRING 3.4 2D DRAWINGS OF SHOCK ABSORBER

3.4.1 BOTTOM
Fig 3.5:-Bottom part
Fig 3.3:- Helical Spring 3.4.2 TOP PART
3.2 TOTAL ASSEMBLY
Fig 3.6:- Top part
3.4.3 HELICAL SPRING PART
Fig 3.4:-Total Assembly
Fig 3.7:-Helical Spring part

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3.5 ASSEMBLY the phenomenal increase in computing power, FEA has been
developed to an incredible precision. Present day
supercomputers are now able to produce accurate results for
all kinds of parameters. FEA consists of a computer model of
a material or design that is stressed and analyzed for specific
results. It is used in new product design, and existing product
refinement. A company is able to verify a proposed design
will be able to perform to the client's specifications prior to
manufacturing or construction. Modifying an existing product
or structure is utilized to qualify the product or structure for a
new service condition. In case of structural failure, FEA may
be used to help determine the design modifications to meet the
new condition. There are generally two types of analysis that
Fig 3.8:- Assembly
are used in industry: 2-D modeling, and 3-D modeling. While
2-D modeling conserves simplicity and allows the analysis to
3.6 MODIFIED SPRING OF SHOCK ABSORBER be run on a relatively normal computer, it tends to yield less
accurate results. 3-D modeling, however, produces more
accurate results while sacrificing the ability to run on all but
the fastest computers effectively. Within each of these
modeling schemes, the programmer can insert numerous
algorithms (functions) which may make the system behave
linearly or non-linearly. Linear systems are far less complex
and generally do not take into account plastic deformation.
Non-linear systems do account for plastic deformation, and
many also are capable of testing a material all the way to
fracture.
FEA uses a complex system of points called nodes which

Fig 3.9:-Modified spring of shock absorber make a grid called a mesh. This mesh is programmed to
contain the material and structural properties which define
3.7 MODIFIED SPRING how the structure will react to certain loading conditions.
Nodes are assigned at a certain density throughout the material
depending on the anticipated stress levels of a particular area.
Regions which will receive large amounts of stress usually
have a higher node density than those which experience little
or no stress. Points of interest may consist of: fracture point of
previously tested material, fillets, corners, complex detail, and
high stress areas. The mesh acts like a spider web in that from
each node, there extends a mesh element to each of the
adjacent nodes. This web of vectors is what carries the
material properties to the object, creating many elements.
Fig 3.10:-Modified spring A wide range of objective functions (variables within the
system) are available for minimization or maximization:
 Mass, volume, temperature
 Strain energy, stress strain
4. INTRODUCTION TO FEA
Finite Element Analysis (FEA) was first developed in 1943 by  Force, displacement, velocity, acceleration
R. Courant, who utilized the Ritz method of numerical  Synthetic (User defined)
analysis and minimization of variational calculus to obtain
approximate solutions to vibration systems. Shortly thereafter, There are multiple loading conditions which may be applied to
a paper published in 1956 by M. J. Turner, R. W. Clough, H.
 Point, pressure, thermal, gravity, and centrifugal
a system. Some examples are shown:
C. Martin, and L. J. Topp established a broader definition of
numerical analysis. The paper centered on the "stiffness and
 Thermal loads from solution of heat transfer analysis
static loads
deflection of complex structures". By the early 70's, FEA was
limited to expensive mainframe computers generally owned  Enforced displacements
by the aeronautics, automotive, defense, and nuclear  Heat flux and convection
industries. Since the rapid decline in the cost of computers and
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 Point, pressure and gravity dynamic loads and others will have prescribed loads. These models can be
extremely time consuming to prepare, and commercial codes
Each FEA program may come with an element library, or one vie with one another to have the most user-friendly graphical
“preprocessor" to assist in this rather tedious chore. Some of
 Rod elements & Beam elements
is constructed over time. Some sample elements are:
 Plate/Shell/Composite elements
these preprocessors can overlay a mesh on a preexisting CAD
 Shear panel
file, so that finite element analysis can be done conveniently
 Solid elements
as part of the computerized drafting-and-design process.
 Spring elements
 Mass elements
4.2.2 Analysis:
 Rigid elements The dataset prepared by the preprocessor is used as input to
 Viscous damping elements the finite element code itself, which constructs and solves a
system of linear or nonlinear algebraic equations.
Many FEA programs also are equipped with the capability to
use multiple materials within the structure such as: Kijuj = fi
 Isotropic, identical throughout
 Orthotropic, identical at 90 degrees where u and f are the displacements and externally applied
 General anisotropic, different throughout forces at the nodal points; The formation of the K matrix is
dependent on the type of problem being attacked, and this
module will outline the approach for truss and linear elastic
4.1 Types of Engineering Analysis
stress analyses; Commercial codes may have very large
Structural analysis consists of linear and non-linear models. element libraries, with elements appropriate to a wide range of
Linear models use simple parameters and assume that the problem types. One of FEA's principal advantages is that
material is not plastically deformed. Non-linear models consist many problem types can be addressed with the same code,
of stressing the material past its elastic capabilities. The merely by specifying the appropriate element types from the
stresses in the material then vary with the amount of library.
deformation as in. Vibrational analysis is used to test a
material against random vibrations, shock, and impact. Each 4.2.3 Post-processing:
of these incidences may act on the natural Vibrational
frequency of the material which, in turn, may cause resonance In the earlier days of finite element analysis, the user would
and subsequent failure. Fatigue analysis helps designers to pore through reams of numbers generated by the code, listing
predict the life of a material or structure by showing the displacements and stresses at discrete positions within the
effects of cyclic loading on the specimen. Such analysis can model. It is easy to miss important trends and hot spots this
show the areas where crack propagation is most likely to way, and modern codes use graphical displays to assist in
occur. Failure due to fatigue may also show the damage visualizing the results. Typical postprocessor display overlays
tolerance of the material. Heat Transfer analysis models the colored contours representing stress levels on the model,
conductivity or thermal fluid dynamics of the material or showing a full field picture similar to that of photo elastic or
structure. This may consist of a steady-state or transient moiré experimental results.
transfer. Steady-state transfer refers to constant thermo
properties in the material that yield linear heat diffusion. 5. INTRODUCTION TO ANSYS
ANSYS is general-purpose finite element analysis (FEA)
4.2 Results of Finite Element Analysis software package. Finite Element Analysis is a numerical
FEA has become a solution to the task of predicting failure method of deconstructing a complex system into very small
due to unknown stresses by showing problem areas in a pieces (of user-designated size) called elements. The software
material and allowing designers to see all of the theoretical Implements equations that govern the behavior of these
stresses within. This method of product design and testing is elements and solves them all; creating a comprehensive
far superior to the manufacturing costs which would accrue if explanation of how the system acts as a whole. These results
each sample was actually built and tested. In practice, a finite then can be presented in tabulated, or graphical forms. This
element analysis usually consists of three principal steps. type of analysis is typically used for the design and
optimization of a system far too complex to analyze by hand.
Systems that may fit into this category are too complex due to
4.2.1 Preprocessing:
their geometry, scale, or governing equations.
The user constructs a model of the part to be analyzed in
which the geometry is divided into a number of discrete sub ANSYS is the standard FEA teaching tool within the
regions, or elements," connected at discrete points called Mechanical Engineering Department at many colleges.
nodes." Certain of these nodes will have fixed displacements, ANSYS is also used in Civil and Electrical Engineering, as
__________________________________________________________________________________________
well as the Physics and Chemistry departments. ANSYS 5.2 Specific Capabilities of ANSYS:
provides a cost-effective way to explore the performance of
products or processes in a virtual environment. This type of 5.2.1Structural
product development is termed virtual prototyping. With Structural analysis is probably the most common application
virtual prototyping techniques, users can iterate various of the finite element method as it implies bridges and
scenarios to optimize the product long before the buildings, naval, aeronautical, and mechanical structures such
manufacturing is started. This enables a reduction in the level as ship hulls, aircraft bodies, and machine housings, as well as
of risk, and in the cost of ineffective designs. The multifaceted mechanical components such as pistons, machine parts, and
nature of ANSYS also provides a means to ensure that users tools.
are able to see the effect of a design on the whole behavior of
the product, be it electromagnetic, thermal, mechanical etc. 5.2.2 Static Analysis
5.1 Generic Steps to Solving any Problem in ANSYS: Used to determine displacements, stresses, etc. under static
loading conditions. ANSYS can compute both linear and
Like solving any problem analytically, you need to define (1) nonlinear static analyses. Nonlinearities can include plasticity,
your solution domain, (2) the physical model, (3) boundary stress stiffening, large deflection, large strain, hyper elasticity,
conditions and (4) the physical properties. You then solve the contact surfaces, and creep.
problem and present the results. In numerical methods, the
main difference is an extra step called mesh generation. This is 5.2.3 Transient Dynamic Analysis
the step that divides the complex model into small elements
that become solvable in an otherwise too complex situation. Used to determine the response of a structure to arbitrarily
Below describes the processes in terminology slightly more time-varying loads. All nonlinearities mentioned under Static
attune to the software. Analysis above are allowed.
5.1.1 Build Geometry 5.2.4 Buckling Analysis

Construct a two or three dimensional representation of the Used to calculate the buckling loads and determine the
object to be modeled and tested using the work plane buckling mode shape. Both linear (eigenvalue) buckling and
coordinates system within ANSYS. nonlinear buckling analyses are possible. In addition to the
above analysis types, several special-purpose features are
5.1.2 Define Material Properties available such as Fracture mechanics, Composite material
analysis, Fatigue, and both p-Method and Beam analyses.
Now that the part exists, define a library of the necessary
materials that compose the object (or project) being modeled. 5.2.5 Thermal Analysis
This includes thermal and mechanical properties.
ANSYS is capable of both steady state and transient analysis
5.1.3 Generate Mesh of any solid with thermal boundary conditions. Steady-state
thermal analyses calculate the effects of steady thermal loads
At this point ANSYS understands the makeup of the part. on a system or component. Users often perform a steady-state
Now define how the Modeled system should be broken down analysis before doing a transient thermal analysis, to help
into finite pieces. establish initial conditions. A steady-state analysis also can be
The last step of a transient thermal analysis; performed after
5.1.4 Apply Loads all transient effects have diminished. ANSYS can be used to
Once the system is fully designed, the last task is to burden the determine temperatures, thermal gradients, heat flow rates,
system with constraints, such as physical loadings or boundary and heat fluxes in an object that are caused by thermal loads
conditions. that do not vary over time. Such loads include the following:
· Convection
5.1.5 Obtain Solution
· Radiation
This is actually a step, because ANSYS needs to understand · Heat flow rates
within what state (steady state, transient… etc.) the problem · Heat fluxes (heat flow per unit area)
must be solved. · Heat generation rates (heat flow per unit volume)
· Constant temperature boundaries
5.1.6 Present the Results
A steady-state thermal analysis may be either linear, with
After the solution has been obtained, there are many ways to constant material properties; or nonlinear, with material
present ANSYS’ results, choose from many options such as properties that depend on temperature. The thermal properties
tables, graphs, and contour plots.
__________________________________________________________________________________________
of most material vary with temperature. This temperature magnetic forming (magneto-structural analysis), and micro
dependency being appreciable, the analysis becomes electro mechanical systems (MEMS).
nonlinear. Radiation boundary conditions also make the
analysis nonlinear. Transient calculations are time dependent 5.2.8 Modal Analysis
and ANSYS can both solve distributions as well as create
video for time incremental displays of models. A modal analysis is typically used to determine the vibration
characteristics (natural frequencies and mode shapes) of a
structure or a machine component while it is being designed. It
5.2.6 Acoustics / Vibration Analysis
can also serve as a starting point for another, more detailed,
ANSYS is capable of modeling and analyzing vibrating dynamic analysis, such as a harmonic response or full
systems in order to that vibrate in order to analyze. Acoustics transient dynamic analysis. Modal analyses, while being one
is the study of the generation, propagation, absorption, and of the most basic dynamic analysis types available in ANSYS,
reflection of pressure waves in a fluid medium. Applications can also be more computationally time consuming than a
for acoustics include the following: typical static analysis. A reduced solver, utilizing
Sonar - the acoustic counterpart of radar automatically or manually selected master degrees of freedom
Design of concert halls, where an even distribution of is used to drastically reduce the problem size and solution
sound pressure is desired time.
Noise minimization in machine shops
Noise cancellation in automobiles 5.2.9 Harmonic Analysis
Underwater acoustics
Design of speakers, speaker housings, acoustic filters, Used extensively by companies who produce rotating
mufflers, and many other similar devices. machinery, ANSYS Harmonic analysis is used to predict the
Geophysical exploration sustained dynamic behavior of structures to consistent cyclic
loading. Examples of rotating machines which produced or are
 Gas Turbines for Aircraft and Power Generation

Within ANSYS, an acoustic analysis usually involves Subjected to harmonic loading are:
 Steam Turbines
modeling a fluid medium and the surrounding structure.
 Wind Turbine
Characteristics in question include pressure distribution in the
 Water Turbines
fluid at different frequencies, pressure gradient, and particle
 Turbo pumps
velocity, the sound pressure level, as well as, scattering,
 Internal Combustion engines
diffraction, transmission, radiation, attenuation, and dispersion
 Electric motors and generators
of acoustic waves. A coupled acoustic analysis takes the fluid-
 Gas and fluid pumps
structure interaction into account. An uncoupled acoustic
 Disc drives
analysis models only the fluid and ignores any fluid-structure
interaction. The ANSYS program assumes that the fluid is
compressible, but allows only relatively small pressure
changes with respect to the mean pressure. Also, the fluid is A harmonic analysis can be used to verify whether or not a
assumed to be non-flowing and inviscid (that is, viscosity machine design will successfully overcome resonance, fatigue,
causes no dissipative effects). Uniform mean density and and other harmful effects of forced vibrations.
mean pressure are assumed, with the pressure solution being
the deviation from the mean pressure, not the absolute 6. PRESENT DESIGN
pressure. 6.1 Structural Analysis for bike weight (125kgs) using
5.2.7 Coupled Fields Analysis Spring Steel as spring material
A coupled-field analysis is an analysis that takes into account Case 1: Load 125kgs
the interaction (coupling) between two or more disciplines
(fields) of engineering. A piezoelectric analysis, for example, Element Type Solid 20 node 95
handles the interaction between the structural and electric Material: Spring Steel
fields: it solves for the voltage distribution due to applied Material Properties: Young’s Modulus (EX): 210000N/mm2
displacements, or vice versa. Other examples of coupled-field Poisson’s Ratio (PRXY): 0.29
analysis are thermal-stress analysis, thermal-electric analysis, Density: 0.000007850kg/mm3
and fluid-structure analysis. Some of the applications in which
coupled-field analysis may be required are pressure vessels
(thermal-stress analysis), fluid flow constrictions (fluid-
structure analysis), induction heating (magnetic-thermal
analysis), ultrasonic transducers (piezoelectric analysis),
__________________________________________________________________________________________
6.1.1 Imported Model from Pro/Engineer
Fig 6.3:- Load applied on tetra mesh model
RESULTS AFTER APPLIENG LOADS:
Fig 6.1:- Imported model from Pro/Engineer
6.1.2 Tetra Meshed Model
Fig 6.4:- Displacement Vector Sum
Fig 6.2:- Tetra Meshed model
Loads
Pressure – 0.0078N/mm2 Fig 6.5:- Von misses stress
6.2 Structural Analysis for bike weight (125kgs) using

Beryllium Copper as spring material
Case 2: Load 125kg
Element Type: solid 20 node 95
Material: Beryllium Copper
Material Properties: Young’s Modulus (EX) : 280000N/mm2
__________________________________________________________________________________________
Poisson’s Ratio (PRXY): 0.285

Density: 0.000001850kg/mm3
Fig 6.8:-Displacement vector sum
Fig 6.6:- Displacement vector sum
Fig 6.9:-Van misses stress
Fig 6.7:-Von misses stress 6.3 Structural Analysis for one person and bike
weight(200kgs) using
6.3 Structural Analysis for one person and bike
weight (200kgs) using Spring Steel as spring material
Case 4: Load 200kgs
Case 3: Load 200kg
Element Type Solid 20 node 95
Material: Spring Steel
Material Properties: Young’s Modulus (EX) : 210000N/mm2
Poisson’s Ratio (PRXY) : 0.29
Density: 0.000007850kg/mm3
__________________________________________________________________________________________

Case 2: Load 125kgs
Fig 6.11:- Von misses stress
7. NEW MODIFIED DESIGN

Spring Steel as spring material
Case 1: Load 125kgs

weight(200kgs) using Spring Steel as spring material
Case 3: Load 200kgs
Fig 7.2:-Von misses stress Fig 7.5:- Displacement vector sum
__________________________________________________________________________________________
8. RESULTS TABLE:
8.1 PRESENT DESIGN
Fig 7.6:-Von Misses Stress

weight (200kgs) using Beryllium Copper as spring
material
Case 4: Load 200kgs
8.2 MODIFIED DESIGN
__________________________________________________________________________________________
CONCLUSIONS
[1]. In this project we have designed a shock absorber
used in a 150cc bike. We have modeled the shock
absorber by using 3D parametric software
Pro/Engineer.
[2]. To validate the strength of our design, we have done
structural analysis and modal analysis on the shock
absorber. We have done analysis by varying spring
material Spring Steel and Beryllium Copper.
[3]. By observing the analysis results, the analyzed stress
values are less than their respective yield stress
values. So our design is safe.
[4]. By comparing the results for both materials, the stress
value is less for Spring Steel than Beryllium Copper .
[5]. Also the shock absorber design is modified by
reducing the diameter of spring by 2mm and
structural, modal analysis is done on the shock
absorber. By reducing the diameter, the weight of the
spring reduces. By comparing the results for both
materials, the stress value is less for Spring Steel than
Beryllium Copper.
[6]. By comparing the results for present design and
modified design, the stress and displacement values
are less for modified design.
[7]. So we can conclude that as per our analysis using
material spring steel for spring is best and also our
modified design is safe.
REFERENCES
[1]. Machine design by R.S.KURMI
[2]. PSG,2008.”DESIGN DATA,” kalaikathir achachgam
publishers, COIMBATORE, INDIA
[3]. Automobile Engineering by R.B.Gupta
[4]. Automobile Engineering by G.B.S. Narang.
[5]. Automobile Servicing and Maintenance by K.Ashrif
Ali
[6]. Automotive Maintenance and Trouble Shooting by
Ernest Venk,& Edward D. Spicer
__________________________________________________________________________________________

Design and Analysis of A Shock Absorber

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IJRET: International Journal of Research in Engineering and Technology ISSN: 2319-1163

DESIGN AND ANALYSIS OF A SHOCK ABSORBER

Pinjarla.Poornamohan1, Lakshmana Kishore.T2

1. INRODUCTION 1.3 Applications

1.4 Vehicle suspension simple hand tools. A disadvantage is that the

 Hysteresis of structural material, for example the

 Dry friction as used in wheel brakes, by using disks

1.7.6 Self compensating Hydraulic 2. INTRODUCTION TO PRO/ENGINEER

2.1 Summary of capabilities

Fig 3.2:- Top part

3.1.3 HELICAL SPRING 3.4 2D DRAWINGS OF SHOCK ABSORBER

Fig 3.5:-Bottom part

Fig 3.3:- Helical Spring 3.4.2 TOP PART

3.2 TOTAL ASSEMBLY

Fig 3.6:- Top part

3.4.3 HELICAL SPRING PART

Fig 3.4:-Total Assembly

Fig 3.7:-Helical Spring part

FEA uses a complex system of points called nodes which

5.1.1 Build Geometry 5.2.4 Buckling Analysis

 Gas Turbines for Aircraft and Power Generation

6.1.1 Imported Model from Pro/Engineer

Fig 6.3:- Load applied on tetra mesh model

RESULTS AFTER APPLIENG LOADS:

Fig 6.1:- Imported model from Pro/Engineer

6.1.2 Tetra Meshed Model

Fig 6.4:- Displacement Vector Sum

Fig 6.2:- Tetra Meshed model

6.2 Structural Analysis for bike weight (125kgs) using

Poisson’s Ratio (PRXY): 0.285

Fig 6.8:-Displacement vector sum

Fig 6.6:- Displacement vector sum

Fig 6.9:-Van misses stress

Fig 6.10:-Displacement vector sum

7.2 Structural Analysis for bike weight (125kgs) using

Fig 6.11:- Von misses stress

7. NEW MODIFIED DESIGN

Fig 7.4:- Von misses stress

7.3 Structural Analysis for one person and bike

Fig 7.2:-Von misses stress Fig 7.5:- Displacement vector sum

Fig 7.6:-Von Misses Stress

7.6 Structural Analysis for one person and bike

8.2 MODIFIED DESIGN

Fig 7.7:- Displacement vector sum

Fig 7.8:- Von misses stress

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