DESIGN, MODELING AND PERFORMANCE ANALYSIS OF PSD

SHOCK ABSORBER USING ANSYS

S.Ramanjaneyulu1, B. Geetha Chandra Sekhar2, [Link] Krishna3
1,3
Assistant Professor, Mechanical Engineering, Lendi Institute of Engineering & Technology,
Vizianagaram, Andhra Pradesh, India
2
Assistant Professor, Mechanical Engineering, Anil Neerukonda Institute of Technology &
Sciences, Visakhapatnam, Andhra Pradesh, India

Abstract 1. Introduction
Shock absorbers are a critical part of a 1.1 FUNCTIONS OF SHOCK ABSORBERS IN
suspension system, connecting the vehicle to AUTOMOBILE
its wheels. The need for dampers arises In common with carriages and railway
because of the roll and pitches associated with locomotives, most early motor vehicles used leaf
vehicle manoeuvring, and from the roughness springs. One of the features of these springs was
of roads. In the mid nineteenth century, road that the friction between the leaves offered a
quality was generally very poor. The rapidly degree of damping and in a 1912 review of
increasing power available from the internal vehicle suspension the lack of this characteristic
combustion engine made higher speeds in helical springs was the reason it was
routine; this, plus the technical aptitude of the "impossible" to use them as main springs.
vehicle and component designers, coupled However the amount of damping provided by
with a general commercial mood favoring leaf spring friction was limited and variable
development and change, provided an according to the conditions of the springs, and
environment that led to invention and whether wet or dry. It also operated in both
innovation of shock absorbers. directions. Motorcycle front suspension adopted
Shock absorbers are devices that coil sprung Druid forks from about 1906, and
smooth out an impulse experienced by a similar designs later added rotary friction
vehicle, and appropriately dissipate or absorb dampers, which damped both ways - but they
the kinetic energy. One of the problems is that were adjustable (e.g. 1924 Webb forks).
the vehicle bounce continuously more than These friction disk shock absorbers were
one times and it is called as bouncing also fitted to many cars. One of the problems
problems. Shock absorbers have become such with motor cars was the large variation in sprung
an essential component of an automobile. So weight between lightly loaded and fully loaded,
that the objective of this project is to study the especially for the rear springs. When heavily
causes of the bouncing problem at the vehicle loaded the springs could bottom out, and apart
and to compare the failure parts performance from fitting rubber 'bump stops', there were
in terms of its strength. In this work initially attempts to use heavy main springs with
designing the Hero Honda bike PSD shock auxiliary springs to smooth the ride when lightly
absorber with design data using Solid works loaded, which were often called 'shock
and to test the performance of designed PSD absorbers'. Realising that the spring and vehicle
shock absorber includes structural and model combination bounced with a characteristic
analysis using ANSYS tool at various loading frequency, these auxiliary springs were designed
conditions with a different period, but were not a solution to
Keywords: PSD Shock absorber, Solid works, the problem that the spring rebound after striking
Stress, Deformation, Strains, ANSYS, a bump could throw you out of your seat. What
Damping. was called for was damping that operated on the
rebound.

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The purpose of a shock absorber, within system, connecting the vehicle to its wheels.
any moving object, is to dissolve the kinetic Basically shock absorbers tend to be products
energy evenly while eliminating any which lessen a good behavioral instinct skilled
decelerating force that may be destructive to the with an automobile, as well as properly absorb
object. Shock absorbers are an important part of the actual kinetic power. Almost all suspension
automobile and motorcycle suspensions, aircraft systems consist of springs and dampers, which
landing gear, and the supports for many tend to limit the performance of a system due to
industrial machines. Large shock absorbers have their physical constraints. Suspension systems,
also been used in structural engineering to reduce comprising of springs and dampers are usually.
the susceptibility of structures to earthquake 1.2 TYPES OF VEHICLE SHOCK
damage. A transverse mounted shock absorber, ABSORBERS
helps keep railcars from swaying excessively Diagram of the main components of a twin-tube
from side to side and are important in passenger and mono-tube shock absorber Most vehicular
railroads systems because they prevent railcars shock absorbers are either twin-tube or mono-
from damaging station platforms. In a vehicle, it tube types with some variations on these themes.
reduces the effect of travelling over rough
ground, and leading to improved ride quality.
Without shock absorbers, the vehicle would have
a bouncing ride, as energy is stored in the spring
and then released to the vehicle, possibly
exceeding the allowed range of suspension
movement. A prototype shock absorber capable
of significantly reducing vibrations, such as
those experienced while driving, has been
developed by German researchers. The device
can also convert vibrations into energy, meaning
it has the potential to power inaccessible sensors.
Shock absorbers are devices that dampen
unwanted vibrations. Most are passive in nature
and made of materials called elastomers that are
yielding and malleable.
The main advantage over the friction disk
dampers was that it would resist sudden
movement but allow slow movement, whereas a) Basic twin-tube
the rotary friction dampers tended to stick and b) Twin-tube gas charged
then offer the same resistance regardless of speed c) Position sensitive damping Often
of movement. There appears to have been little abbreviated simply as "PSD", this design is
progress on commercialising the lever arm shock another evolution of the twin-tube shock. In a
absorbers until after World War I, after which PSD shock absorber, which still consists of two
they came into widespread. A suspension system nested tubes and still contains nitrogen gas, a set
or shock absorber is a mechanical device of grooves has been added to the pressure tube.
designed to smooth out and dissipate kinetic These grooves allow the piston to move
energy. The shock absorbers function is to relatively freely in the middle range of travel
absorb or dissipate energy. In a vehicle, it (i.e., the most common street or highway use,
reduces the effect of traveling over rough called by engineers the "comfort zone") and to
ground, leading to improve ride quality, and move with significantly less freedom in response
increase in comfort due to substantially reduced to shifts to more irregular surfaces when upward
amplitude of disturbances. and downward movement of the piston starts to
Basic safety and also traveling ease and occur with greater intensity (i.e., on bumpy
comfort to get a car‘s motorist are usually sections of roads— the stiffening gives the driver
equally influenced by the particular vehicle‘s greater control of movement over the vehicle so
suspension method. Safety refers to the vehicle‘s its range on either side of the comfort zone is
handling and braking capabilities. Shock called the "control zone"). This advance allowed
absorbers are a critical part of a suspension car designers to make a shock absorber tailored

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to specific makes and models of vehicles and to the disturbance and the relative damping factor
take into account a given vehicle's size and are implemented. The evaluation of vehicle
weight, its maneuverability, its horsepower, etc. suspension efficiency based on the values of
in creating a correspondingly effective shock. inefficient force pulse ratio for known efficient
d) Acceleration Sensitive Damping control algorithms of elastic-damping
e) Coil over characteristic of pneumatic shock absorber.
f ) Mono-tube Mr. Sudarshan Martande [Link] Shock
g) Spool valve absorbers are a critical part of a suspension
system, connecting the vehicle to its wheels. The
2. LITERATURE REVIEW need for dampers arises because of the roll and
Tongyi Xu [Link] studied the two- pitches associated with vehicle maneuvering,
terminal mass (TTM) based vibration absorber and from the roughness of roads. In the mid
with variable moment of inertia (VMI) for nineteenth century, road quality was generally
passive vehicle suspension is proposed. The very poor. The rapidly increasing power
VMI of the system is achieved by the motion of available from the internal combustion engine
sliders embedded in a hydraulic driven flywheel. made higher speeds routine; this, plus the
The moment of inertia increases in reaction to technical aptitude of the vehicle and component
strong vertical vehicle oscillations and decreases designers, coupled with a general commercial
for weak vertical oscillations. The hydraulic mood favoring development and change,
mechanism of the system converts the relative provided an environment that led to invention
linear motion between the two terminals of the and innovation of shock absorbers. Shock
suspension into rotating motion of the flywheel. absorbers are devices that smooth out an impulse
In the case of stronger vehicle vertical experienced by a vehicle, and appropriately
oscillation, the sliders inside the flywheel move dissipate or absorb the kinetic energy. shock
away from the center of the flywheel because of absorbers have become such an essential
the centrifugal force, hence yielding higher component of an automobile even then there has
moment of inertia. The opposite is true in the been no particular method to test it using Finite
case of weaker vehicle oscillation. As such, the Element Analysis technique and most of the
moment of inertia adjusts itself adaptively in testing is done using the physical tests. Thus this
response to the road conditions. The paper focuses on to develop new correlated
performance of the proposed TTM-VMI methodologies that will allow engineers to
absorber has been analyzed via dynamics design components of Shock Absorbers by using
modeling and simulation and further examined FEM based tools.
by experiments. In comparison to its counterpart [Link] [Link] A
with constant moment of inertia, the proposed suspension system or shock absorber is a
VMI system offers faster response, better road mechanical device designed to smooth out or
handling and safety, improved ride comfort, and damp shock impulse, and dissipate kinetic
reduced suspension deflection except in the case energy. The shock absorbers duty is to absorb or
of sinusoidal excitations. dissipate energy. In a vehicle, it reduces the
Ryabov et. al presents the analytical effect of traveling over rough ground, leading to
proof of the presence of two inefficient areas in improved ride quality, and increase in comfort
vehicle suspension oscillation cycle in linear due to substantially reduced amplitude of
shock absorber work. It derived on the basis of disturbances. When a vehicle is traveling on a
analysis of the dynamics equations for the linear level road and the wheels strike a bump, the
single-support single-mass vibrating system with spring is compressed quickly. The compressed
fixed elastic and damping characteristics at spring will attempt to return to its normal loaded
harmonic kinematic disturbance. Expressions of length and, in so doing, will rebound past its
the full, efficient and inefficient work of the normal height, causing the body to be lifted. The
linear damper in one oscillation cycle are weight of the vehicle will then push the spring
derived. There under the equations for down below its normal loaded height. This, in
calculation of the effective shock absorber work turn, causes the spring to rebound again. This
ratio for various types of damping characteristics bouncing process is repeated over and over, a
are determined. The graphs of the effective shock little less each time, until the up-and-down
absorber work ratio on the relative frequency of movement finally stops. If bouncing is allowed

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to go uncontrolled, it will not only cause an varying the wire diameter of the coil spring to
uncomfortable ride but will make handling of the verify the best dimension for the spring in shock
vehicle very difficult. The design of spring in absorber. Modeling and Analysis is done using
suspension system is very important. In this Pro/ENGINEER and ANSYS respectively.
project a shock absorber is designed and a 3D A.K. Samantaray Preloaded liquid
model is created using Pro/Engineer. The model spring/damper based shock isolation systems are
is also changed by changing the thickness of the suitable for heavy load military applications. In
spring. Structural analysis and modal analysis this paper, mathematical models are developed
are done on the shock absorber by varying for passive liquid spring shock absorbers. The
material for spring, Spring Steel and Beryllium preloading is achieved by mounting the load
Copper. The analysis is done by considering between two liquid spring/dampers. Dynamics
loads, bike weight, single person and 2 persons. of such shock absorbers involve coupled
Structural analysis is done to validate the hydrodynamic and thermodynamic phenomena.
strength and modal analysis is done to determine The energy dissipated through orifice due to
the displacements for different frequencies for hydrodynamic losses heats up the working fluid
number of modes. Comparison is done for two and consequently the heat is dissipated to
materials to verify best material for spring in environment. Such multienergy domain
Shock absorber. Modeling is done in interaction is well represented in this paper by
Pro/ENGINEER and analysis is done in ANSYS. using bond graph models. Moreover, the
Pro/ENGINEER is the standard in 3D product developed model accounts for the strain-rate
design, featuring industry-leading productivity dependent damping offered by the compressible
tools that promote best practices in working fluid in the liquid spring. The results
[Link] is general-purpose finite element show that proper choice of preloading and
analysis (FEA) software package. Finite Element geometric parameters (spring dimensions and
Analysis is a numerical method of orifice sizes) can, respectively, reduce the
deconstructing a complex system into very small thermodynamic and strain-rat e dependent
pieces (of user-designated size) called elements. damping phenomena.
Prince Jerome Christopher J. et. al In 3. DESIGN AND MODELLING PSD
vehicles problem happens while driving on SHOCK ABSORBER USING
bumping road condition. The objective of this SOLIDWORKS DESIGN TOOL
project is to design and analyze the performance To simulate and designing the PSD shock
of Shock absorber by varying the wire diameter absorber with available hero Honda bike data
of the coil spring. The Shock absorber which is and also it consists of top rod with stainless steel,
one of the Suspension systems is designed piston rod with forged steel, spring with carbon
mechanically to handle shock impulse and steel and screw with stainless steel materials. For
dissipate kinetic energy. It reduces the amplitude designing and modeling of PSD shock absorber
of disturbances leading to increase in comfort using solidworks design tool and the designed
and improved ride quality. The spring is PSD shock absorber is exported to IGES
compressed quickly when the wheel strikes the or .STEP file to analyze the performance of PSD
bump. The compressed spring rebound to its shock absorber at various loading conditions. For
normal dimension or normal loaded length which evaluating the performance of PSD shock
causes the body to be lifted. The spring goes absorber using ANSYS workbench tool, by
down below its normal height when the weight using this tool modal and static structural
of the vehicle pushes the spring down. This, in analysis are performing later stage.
turn, causes the spring to rebound again. The 3.1 PSD shock absorber parts design data
spring bouncing process occurs over and over For designing and modeling of PSD
every less each time, until the up-and-down shock absorber using solidsworks tool required
movement finally stops. The vehicle handling design data which are represented in line
becomes very difficult and leads to diagrams. PSD shock absorber contains four
uncomfortable ride when bouncing is allowed parts those are
uncontrolled. Hence, the designing of spring in a i. Top rod, ii. Piston rod, iii. Spring,
suspension system is very crucial. The analysis [Link]
is done by considering bike mass, loads, and no
of persons seated on bike. Comparison is done by

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3.2 Design and Modeling of PSD Shock Absorber Parts in Solids Works
3.2.1 Designing of Top Rod

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The above diagram represents the it up to 70 mm. Now select the back face and
designing procedure of top rod using solidworks draw a circle with diameter 24mm and extrude it
design tool. Making the first part of the design [Link] the edge and apply fillet with 6mm
lets take top plane and draw the circle with radius. Cutting the sections by leaving the 15 mm
required dimension then exit from the sketch and gap. Take the cutting surface and draw circles
extrude it. Again select the top plane then draw with 8 and 18mm diameter and extrude by
the circle with 10mm diameter and then extrude applying convert entities. The part is completed.

3.2.2 Designing of Piston Rod

The above diagram represents the part. Take the another edge and draw a circle
designing procedure of piston rod using with 27mm diameter and extrude it up to
solidworks design tool. Select a top plane, draw [Link] select the down surface and
a circle with 24mm diameter and extrude it draw a circle then do a extruded cut up to 70mm
108.93mm. Select a edge and fillet it to length. Do the threading up to 50mm using helix
[Link] cut the section as like in the first command

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.
2.2.3 Designing of spring

The above diagram represents the designing front plane draw a circle with diameter 7.25mm
procedure of spring using solidworks design tool. and put 15mm distance from the line. Exit from
Select a front plane and draw a line in downward the sketch go to feature and select swept boss.
direction and then give dimension. Again select a Then the required spring will be obtained.

2.2.4 Designing of screw

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The above diagram represents the designing [Link] top face ,draw center lines and
procedure of screw using solidworks design draw a circle with 2 mm radius. Draw the lines
tool. Select top plane sketch a circles with from circle to outer circle the angle between the
52mm outer diameter and 24mm inner lines is 60 degrees and then trim the circle. Now
diameter. Extrude it [Link] a circle apply the polar array then apply extrude cut.
with 29mm diameter and again extrude it with Then the required screw is obtained.
2.2.5 Assembling of PSD shock absorber using solid works

The above diagram represents the designing 4. PERFORMANCE ANALYSIS OF PSD

procedure of assempbled PSD shock absorber SHOCK ABSOBER USING ANSYS
using solidworks design tool. Select top plane Once the modeling and assembly of PSD
sketch a circles with 52mm outer diameter and shock absorber completed using solidworks, the
24mm inner diameter. Extrude it [Link] FEM analysis has been performed in workbench
a circle with 29mm diameter and again extrude it to identify the load carrying capacity of the PSD
with [Link] top face ,draw center lines and shock absorber at various loading conditions. The
draw a circle with 2 mm radius. Draw the lines steps followed to perform analysis are listed
from circle to outer circle the angle between the below. Material dataof gear is tabulated in ta ble
lines is 60 degrees and then trim the circle. Now 4.1
apply the polar array then apply extrude cut. Then
the required screw is obtained.

Figure 4.1 Imported PSD shock absorber geometry Fig 4.2 Meshed model of PSD shock absorber

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(a) Contact between top rod and piston rod (b) Contact between piston rod, spring and screw

( c) Contact between top rod and screw (d) Contact between screw and spring

load, And support were applied to both sides.

Constrains are given according to FEA. Later a
load of 1000 N to 2000N has been taken as a
passengers load and 1000N to 20000N
damping load to PSD shock absorber as
boundary conditions. Conditions of loads are
shown in figure 4.4.

5. RESULTS AND DISCUSSIONS

5.1 FEM analysis of Von- Mises strains for
PSD shock absorbers
Creating contacts After the succsive PSD shock absorber analyzed under the
completion of above step applying the contact above conditions for the generation of von-
reagions for PSD shock absorber. In this PSD Mises strains, total deformation and stress
shock absorber obtained a 5 contact. The intensity at critical locations. The linear static
acquired contact portions are shown in figure finite element analysis was performed using
4.3, and the no separation contact with FEM. The equivalent von Mises strains
automatic contact tool has been used to create maximum occurred and thatload considered as
contact surfaces. critical load for PSD shock absorber
Applying boundary conditions and performance with passenger load 1000 N and
loads Since the generated PSD shock absorber the critical load is 12000 N. The equivalent von
in contact and suspension nature, then force is Mises strains maximum occurred and that load
applied to the both sides including one side considered as critical load for PSD shock
passengers load and other side sudden damping absorber performance with passenger load

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1000 N and the critical load is 11000 N critical figure from [Link] von mass stress at different
locations for PSD shock absorber in below load shown in tables 5.3-4.

Figure 5.1(a-c) von- mises stresses of PSD shock absorber at different passenger and
damping load

Table 5.1 von- mises stresses (MPa) PSD shock absorber Table 5.2 von- mises stresses
(MPa) PSD shock absorber at at passenger load 1000N passenger load 2000N

5.2 FEM analysis of Von- Mises strains for passenger load 1000 N and the critical load is
PSD shock absorbers 12000 N. The equivalent von Mises strains
PSD shock absorber analyzed under the above maximum occurred and that load considered as
conditions for the generation of von-Mises critical load for PSD shock absorber
strains, total deformation and stress intensity at performance with passenger load 1000 N and
critical locations. The linear static finite the critical load is 11000 N critical locations for
element analysis was performed using FEM. PSD shock absorber in below figure from
The equivalent von Mises strains maximum [Link] von mass stress at different load shown
occurred and thatload considered as critical in tables 5.3-4.
load for PSD shock absorber performance with

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Figure 5.2(a-c) von- mises strains of PSD shock absorber at different passenger and
damping load
Table 5.3 von- mises strains (MPa) PSD shock absorber 5.4 von- mises strains (MPa) PSD
shock absorber at passenger load 1000N Table passenger at load 2000N

5.3 FEM analysis of total deformations for deformation maximum occurred and that load
PSD shock absorbers considered as critical load for PSD shock
PSD shock absorber analyzed under the absorber performance with passenger load
above conditions for the generation of von- 1000 N and the critical load is 11000 N critical
Mises strains, total deformation and stress locations for PSD shock absorber in below
intensity at critical locations. The linear static figure from [Link] von mass stress at different
finite element analysis was performed using load shown in tables 5.5-6.
FEM. The maximum deformation maximum
occurred and that load considered as critical
load for PSD shock absorber performance with
passenger load 1000 N and the critical load is
12000 N. The equivalent maximum

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Figure 5.3 (a-c) Total deformations of PSD shock absorber at different Passenger and
damping load

6. CONCLUSIONS KD chattopadhya, Development of MR

Based on the obtained results of fem analysis at damper Modeling and its Experimental
different load conditions designed PSD shock vibration , The UIP Journal of
absorber is safe at passenger load 1000N and mechanical Engineering , Vol 7th, NO 3,
damping load of 12000N. And also designed 2014.
PSD shock absorber is safe to use up to 4. .Tallbott M.S, An Experimentally
passenger load 1000N and damping load of Validated Physical Model of high
12000N and damping loads. performance damper, M.S Thesis,
Purdue University, Laffayette , 2002.
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