Chapter 4 - Suspension System - Introduction To Automotive Engineering
Chapter 4 - Suspension System - Introduction To Automotive Engineering
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Chapter 3: Tires Chapter 5: Braking System
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Chapter 4
Suspension System
4.1 Introduction
Suspension is the system that connects a vehicle to its wheels and allows
relative motion.
Mechanical
pneumatic
hydraulic system
Air has been used on vehicles at varying frequencies and with mixed
success. Air systems can also be used as a means of achieving height
adjustment in the vehicle. Air suspension has an added advantage in that
the controller can also perform the task of leveling the car if height
sensors are placed in each spring. Existing air springs do have the
drawback that they cannot simply replace a coil spring in all their
behavioral properties. While the properties of air suit heavy vehicle
transport they are not as easily put to work underneath a light
automobile. Their lack of popularity within smaller vehicles is also due to
their elevated cost when compared to a coil spring.
When the pedal is pressed repeatedly by the driver, the fluid is sucked
from the reservoir tank then pressurized into the main cylinder through
the tube. The pressurized fluid pushes the piston, then the vehicle
increases ride height from the ground. If the driver needs to decrease the
ride height of the vehicle he simply opens the valve then the fluid
comeback to the reservoir tank.
Pedal
Main cylinder
Piston
Actuator cylinder
Plunger
Reservoir cylinder
Spring
Ball valve
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Table 4.1 Concept scoring.
Concept variant
Noiseless + - 0 0
Leaky less + - + 0
Cost 0 - + 0
Easy + + - 0
Efficiency + 0 - 0
Plus 4 1 2 0
Minus 0 3 2 0
Same 1 1 1 0
Net 4 -2 0 0
Rank 1 3 2 0
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Table 4.2 Concept screening: (based on this table hydraulic system is
used).
Hydraulic Mechanical
Rank 1 2
Continue Yes No
Ground clearance 20 cm
Tires 195/65/R15
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Figure 4.4 3D view of hydraulic suspension vehicle.
Figure 4.5 Model number of the car that we are working on, Honda
Civic.
Where piston is the force that the driver applies on the pedal.
The pedal socket can be at equilibrium when the force and the momentum
should be balanced.
(4.1)
this happens when the operator up strokes or moves the pedal rise up;
this can be shown diagrammatically as follows
Where hA – the distance through which the piston in the pump moves.
θ – The maximum angle through which the pedal moves with horizontals.
Now,
(4.2)
Considering Pascal’s low of the fluid or oil in the cylinder of the vehicle
When valve 1 is closed then the oil’s route or path is actuating the
cylinders
Fr this route or path the pressure is constant all over the path(if valve
1 is closed)
Where p- is the pressure require in the fluid require to hold the piston in
equilibrium and
(4.3)
In order to bring the piston to its maximum possible position the actuator
cylinder must be moved’ times up and down n is in other words called the
number of stroke needs to which the maximum lift height volume of
cylinder filled to move the piston
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(4.4)
Now we have got four equations containing the unknown parameter of the
geometry.
But this holds true when the pedal is a horizontal position; when the pedal
is deflected by an angle θ then the reaction force R2 is given by
When the pedal is at the horizontal position then then the reaction force
becomes then θ = 0 then the reaction force becomes
(1)
(2)
(3)
(4)
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Figure 4.10 Connection of piston and cylinder.
Let the range of the force the driver can apply on the pedal vary from
200–400N
Let the length of the socket b/n the hole of the pin joint X vary from
30–40mm
Now the driver wants to apply a force of 260N on the pedal the iteration
will produce as follow with an objective of finding the possible number of
strokes to practically raise the piston up to the indicated maximum lift
height
As can be seen from Table 4.3, we made five iterations to calculate the
unknown over the indicated range of the assumed value, although many
designers select a different iterative approach objective. We have selected
the optimum and frequently observed number of strokes to be our
objective of the iteration process looks the two extremes of the iteration,
that is, iteration number 1 and number 2. The first one is too much to be
used for 20 KN load and it is mostly stroke number for loads high in
nd
magnitude and number 5 is too small to raise the load, thus the 2
iteration contains the most practicable number of stocks, that is n = 22.2.
Then the processing design analysis of each part will depend on the value
rd
of parameters obtained from the 3 iteration.
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Table 4.3 Iteration.
No H H P L X d1 θ d2 = hA = R2 = n=
2 2
iter min max d1√R2/20 xsinθ (X+L) d1 *242/d2 *hA
p/XCOSθ
= 2+20 =22cm
Piston rod is made of high tensile Stainless steel materials with chromium
plating to avoid corrosion and wear. The selection of materials depends
on the buckling of the piston rod.
Material selection;
Grade ASTM-A36
Yield strength σy = 250 Mpa
Shear strength τ = 145 Mpa
Modulus of elasticity = 200Gpa
Objectives
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To check the safety of the piston by comparison of critical load with
applied load.
Design procedure
If the length of the rod to least cross-sectional dimension ratio is less than
or equal to 11. Then the piston rod is considered as stressed; otherwise it
is considered as column.
So, the piston is short and will fail due to compressive stress
2
125 Mpa = Fcr/((πdp )/4) Where dpispiston diameter Fcr =critical load
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So, we can take the new diameter of the piston to all other parameters
found during the geometry analysis with depend on the geometry of the
piston rod.
C=2 for one end fixed and other pivoted since the piston is kept over the
fluid in one end which is move free and the other end is mounted fixed
This is the critical load for buckling so the piston rod will never fail due to
buckling for the given F = 5KN load
The head of the thickness is taken as a uniform circular flat plate. The
pressure of the oil acts up in the plate uniformly. We can select the
material that
we have used in the piston rod using the previous mechanical property.
We can use the following equation to find the piston head thickness
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4.3.4 DESIGN OF MAIN CYLINDER
The basic function of the hydraulic cylinder is to convert fluid power into
linear machine lift force at that time the cylinder is subjected to internal
pressure of the fluid or oil. Since the internal pressure should be high
enough to sustain the load then the cylinder must be a heavy-duty
cylinder which is expected to be thick to sustain the pressure.
Material selection
Both cast and drawn materials can be selected as cylinder materials for
variable height vehicle but the most frequently selected material is called
cold drown deep polished low carbon steel with relatively high stress
value.
But due to the following reasons we have selected the stainless steel with
mechanical properties given below as cylinder material
Manufacturing feasibility
Local availability
Grade AISI302
Design snalysis
The wall develops both tangential and radial stress with valves which
depend upon the radius.
Now the pressure and the thickness can be analyzed using Lame’s
⬆
equation as follows.
The cylinder is subjected to both radial and tangential stress σr and σt.
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Figure 4.13 Pressure acting on cylinder.
is maximum at x =
ri and 0 at x = ro
Now we can use the maximum strain energy theory to evaluate the
cylinder failure, Where Bernie equation is derived to calculate the cylinder
thickness.
From geometric analysis the internal diameter of the main cylinder was
found to be d1 = 14cm for diameter of the piston rod (dp=8cm), but
during piston design dp was corrected to 7cm
Thus the modified main cylinder is;
d1 = 7+2(head thickness of piston) +2(clearance between piston head and
the cylinder)
d1 = 7+2+2c
= 7+2(1.5) +2(1)
= 10cm
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Where, d1- ismain cylinder diameter.
Material selection
The reservoir only stores the oil and is not subjected to any type of iron
used in pipe manufacture and can be selected as previous cylinder
material but its inner walls are chromium plated to prevent corrosion and
wear. All the oil that fills the main cylinder comes from the reservoir by
way of the tube.
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Let assume that h = 50cm
Availability
Manufacturing feasibility
Design analysis
Tangential stress
where
d2=internal diameter
o
d2 = outer diameter
Thus
⬆
o
d2 = 67mm
Material selection is the same material as the main piston which can be
used as plunger material.
Design analysis
If the length hp is large relative to its diameter then the force may cause
buckling
Now to find the plunger lead thickness tpl we use the following equation
lead thickness
pmax = 324.8Kpa
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Height of the piston,
The inner seal is located 8mm below the upper surface of the plate
a=8mm the thickness of the seal t is to be determined in seal design tb =
15mm geometry analysis.
Thickness of pipe
3 3
Let assume that Q = 40 m /min V = 2000 m /min
From the weight of the car and diameter of cylinder. We got pressure of
324.8Kpa.
From Table 8.2, we find for steel pipe c=3mm there for thickness of the
pipe and σt = 40 Mpa
Material selection
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Figure 4.19 Spring.
Na N-2 N N-1
The ends are square and ground ended because springs with this end are
frequently mounted on a bottom-type seat or on a socket with a depth
equal to the height of just a few coil for the purpose of locating the spring.
STEP ONE:
Which is safe with typical machinery spring having C value from 5-12
Wahl factor,
Stress in spring at F = Fo
As spring is compressed it gets twisted and thus the shear stress may be
expressed as:
STEP THREE
T= Torque
L= Wire length
⬆
G= Elasticity modulus of the material in shear
Solid length is the shortest possible length that the spring can have as it is
not fully compressed to the solid length during operation.
STEP FIVE
Design stress from the average stress service for ASTM- (music wire) for:-
Dw = 2 & τ = 895 Mpa & operating stress τo = 870 Mpa from the step the
design is safe.
STEP SIX
BUCKLING –If Lo > 2.63 DM/α the spring will buckle at operating
deflection.
Therefore the free length of 28.3 is less than 52.63 and buckling is
unlikely.
The poppet valve is made tighter to compress the spring and push the ball
which pushes fluid out.
2
Consideration, Shear area = 12.7 mm
2
Tensile strength area = 14.2 mm
Material selection
Cast iron
Design analysis
J = shear stress
Take diameter to be d = 8 mm
D = 15.84mm
Material selection
Malleable cast iron with the following material property can be selected as
pin
ASTM A602
σTENSILE 621Mpa
Design analysis
Material selection
Based on the nature of the load on the ball that is compressive load we
select material which is hardest and strongest steel, which is martensitic
steel.
The pedal is used to transmit force from the human operator to the small
piston called plunger. Also used to pressurize the fluid inside actuator and
push the required force. In order to design it based on shearing and
bending let us put it horizontal and find the minimum shear and bending
diagram.
Assumption
In order to get good functioning and get free space we assume in our
design the operation is made by inserting its holder, and you can take it
from holder while finishing your work.
Material selection
Due to the nature of load applied by the person on the handle we choose
gray cast iron (4.5% C, ASTM A-48).
Assumption
x = 30 mm
Design analysis
The link is connected to the pedal and the base by pin joint. There are two
links used to connect the socket and the base.
Material selection
Malleable cast iron
ASTM A602
σt = 621 Mpa
Let the least cross section of the link is square of side. the link is subjected
to tensile compressive stress due to reaction force R1 = 3.68 KN
Where Acr = cross sectional area of the link which must be the least
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Then
But in practical case the side of the link parallel to the axis of the socket
(handle is larger than the other side) tl1 = tl2 + 2.5 mm = 5 mm, thus the
factor of safety selected above will be higher.
O rings are used in hydraulic cylinder sealing due to their effect need
shape rectangular section rings are not suited for reciprocating motion
and are only in static application; thus secular shaped seal are more
preferable for this; we use o type for both static and dynamic seals.
Material selection
leather
Reasons to select
Locally available
Low cost
Long life
⬆
Figure 4.25 Recommended shape of groove for sealing.
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Figure 4.26 Seal in the main cylinder.
Clearance
E modules of elasticity
Ts sealing thickness
Other seals are also recommended for the manufacturer that each
cylinder is perfectly sealed so that energy is saved by reducing the leakage
of oil through the clearance.
(1)
(2)
(3)
(4)
Measure the car front axle weight Wf = Rf, and the car rear axle weight Wr
= Rr.
(5)
Equlibrium equations,
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The allowable velocity of vehicle before rising in turning is 30km/hr.
But the allowable velocity of vehicle after rising in turning in order not to
roll the vehicle is 22.5km/hr.
Reference
1. Springs - pdf, Web address:
http://abe.ufl.edu/tburks/Presentations/ABE4171/Springs.pdf
(http://abe.ufl.edu/tburks/Presentations/ABE4171/Springs.pdf) Accessed on 18-04-2018.
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