SYNOPSIS

ON
“DESIGN AND MATERIAL OPTIMIZATION OF HELICAL
COIL SUSPENSION”
Abstract:
Conventional helical coil suspensions are heavier and has lower energy
absorption characteristics. To improve vehicle mileage and ensure smoother
ride there is need to develop new design of helical coil suspensions which are
lighter in weight and possesses better energy absorption characteristics.
Structural and fatigue analysis using FEA method on new design of helical coil
(varying cross section) suspension is performed using ANSYS 19 software and
new class of materials known as MMC’s (Metal Matrix Composites) is
employed to achieve better performance of helical coil suspensions. The CAD
model of helical coil suspension is developed using Creo 2.0 design software.
Comparison is made on the basis of output parameters like von-mises stresses,
principal stress, safety factor and strain energy absorption.
1.1 INTRODUCTION
A spring is defined as an elastic body, whose function is to distort when loaded
and to recover its original shape when the load is removed. It is an elastic object
used to store mechanical energy. Springs are usually made out of spring steel.
Small springs can be wound from pre-hardened stock, while larger ones are
made from annealed steel and hardened after fabrication. Some non-ferrous
metals are also used including phosphor bronze and titanium for parts requiring
corrosion resistance and beryllium copper for springs carrying electrical current
(because of its low electrical resistance). When a spring is compressed or
stretched, the force it exerts is proportional to its change in length. Helical
springs are simple forms of springs, commonly used for the suspension system
in wheeled vehicles. Vehicle suspension system is made out of springs that have
basic role in power transfer, vehicle motion and driving. Therefore, springs
performance optimization plays important role in improvement of car dynamic.

Figure 1: Helical coil suspension

The automobile industry tends to improve the comfort of user and reach
appropriate balance of comfort riding qualities and economy. The helical
springs are said to be closely coiled when the spring wire is coiled so close that
the plane containing each turn is nearly at right angles to the axis of the helix
and the wire is subjected to torsion. In other words, in a closely coiled helical
spring, the helix angle is very small; it is usually less than 10 degree. The major
stresses produced in helical springs are shear stresses due to twisting. The load
applied is parallel to or along the axis of the spring. In open coiled helical
springs, the spring wire is coiled in such a way that there is a gap between the
two consecutive turns, as a result of which the helix angle is large. Helical
springs are generally used in two different applications. The first is the role of
compression spring which offers resistance to forces moving two components
towards each other. Typical applications are car suspension and matter spring.
Compression springs typically have their ends end and allowing for easy
mounting. The second common use for helical spring is as a tensioning element.
Springs used in this role resists forces moving in two objects away from each
other. A couple of common tension spring applications include spring scales
and automatic door closers.

1.2 THEORY OF HELICAL COIL SPRINGS

The helical coil springs are made up of a wire coiled in the form of a helix and
are intended for compressive or tensile loads. The cross-section of the wire of
the spring is generally circular and the two main types of helical coil springs are
compression and tension helical springs. Only the compression springs will be
of interest in this study. A typical compression coil spring can be seen in Figure
2.
 Figure 2: Compression Helical Coil Spring

Definitions of the Some Terms Used in Compression Coil Springs

Solid Length: That is the length when the spring is compressed until the coils
come in contact with each other.

LS= n’.d

Free length: It is the length of the spring in the free or unloaded condition.

LF= n’.d + δ max + .15δ max

Figure 3: Free and Solid Length of the Helical Coil Spring

Spring index: The ratio of the mean diameter of the coil to the diameter of the
wire.

D
C= d

Spring rate (stiffness): The load required per unit deflection of the spring.

W
K= δ

Pitch: The axial distance between adjacent coils in uncompressed state.

 P = Free length – Solid length / (n’ – 1)

1.2.1 Stresses in Helical Coil Springs

The spring is under the action of two forces; the axial force (W) and the twisting
moment (T) which can be seen in Figure 4.

Figure 4: Axially Loaded Spring and Free Body Diagram

The torsional shear stress;

The direct shear stress due to axial load W;

The resultant shear stress in the wire becomes;

As a result, the maximum shear stress;

The shear stress diagrams

Figure 4: Torsional Shear, Direct Shear and Resultant Shear Stress Diagrams

1.2.2 Deformation in Helical Coil Springs

The total active length of the coil spring;

l = length of 1 coil * number of coils = πD.n

The axial deflection of the spring;

It is known that
After substitutions, the deflection for an applied load becomes;

Then, the stiffness of the spring can be written as;

LITERATURE REVIEW

Manish Dakhore et.al. [1] has studied value of stress found to be more at the
critical section of the spring as indicated by red colour. Hence possibility of
failure is more at that section compared to other section of spring. This paper is
discusses about locomotive suspension coil springs, their fundamental stress
distribution and materials characteristic. The analysis of locomotive spring is
carried out by considering cases, when the locomotive at the straight path,
curved path and on uphill. This paper also discusses the Experimental analysis
of a helical suspension spring by using strain gauge. The stress analysis for the
forces obtained and for modal and harmonic response has been carried out by
FEA using ANSYS.

Md. Mustak et.al. [2] Studied the used of E-poxy glass materials for the design
of helical suspension spring. The metal coils of helical spring are replaced by e-
poxy carbon. In this work finite element analysis of helical spring is analysed by
using ANSYS, and in out the values of all parameters.

Aamir A. Waghade et.al. [3] have carried out the works on harmonic analysis
of helical suspension spring. In this paper they have introduced the method for
rectangular cross section helical spring. This paper discusses the experimental
analysis of a helical suspension spring by using strain gauge. The stress analysis
for the forces obtained and for modal and harmonic response has been carried
out by FEA analysis.

Achyut P. Banginwar et.al. [4] carried out work on the design and analysis of
shock absorber using finite element analysis in this paper; he discussed about
shock absorbing system by using 3D Pro Engineering Software and validates
the design, he has done structural analysis, modal analysis on the shock
absorber system.

Mehdi Bakhsheshet.al. [5] have studied result found by comparing steel spring
with composite helical spring it has been found to have lesser stress and has the
most value when fiber position has been considered to be in direction of
loading. Also, weight of spring has been reduced shown that changing
percentage of fiber, especially at Carbon/Epoxy composite, does not affect
spring weight.

P.S.Valsange [6] have been presented the review of fundamental stress

distribution, characteristic of helical coil springs. An in-depth discussion on the
parameters influencing the quality of coil springs is also presented. Factors
affecting strength of coil spring, F.E.A. approaches by the researchers for coil
spring analysis are also studied. Reduction in weight is a need of automobile
industry. Thus, the springs are to be designed for higher stresses with small
dimensions. This requires critical design of coil springs. This leads to critical
material and manufacturing processes. Decarburization that was not a major
issue in the past now becomes essential, to have better spring design.

Vijayeshwar BV. et al. [7] In this research paper they evaluated the
manufacturing of helical coil suspension springs as per requirement. The
objective of this work is a comparative study and analysis of suspension helical
coil spring with two different materials like Chrome Silicon and Hard drawn
carbon steel. They designed the shock absorber model using Pro/E Creo 2.0 and
analysis of stress and deflection they used ANSYS 15.0. After the theoretical
and ANSYS results shows that Chrome silicon spring steel is the optimum
suitable material with low weight and high stiffness for helical spring
applications like mono shock suspensions in bikes and many more.
N. Sai Kumar and Prof. R. Vijay Prakash [8] in this research paper they have
design and analyse the performance of the shock absorber by varying the wire
diameter of the coil spring. They explain all types of shock absorber properties
and using metal spring wire. They consider various types of motorbike spring
specification and modelling of suspension springs. They used alloy steel.
Chrome vanadium steel of spring materials. They determine the analysis of
maximum shear stress, maximum principal stress, normal stress, strain,
maximum principle strain, normal strain, total deformation are noted. The
results of alloy steel are showing the best results in three vehicles (Among there
for Yamaha alloy steel got the least stress). The alloy steel is preferable
compared to chrome vanadium steel.

Suraj R. Bhosle et al. [9] In this research paper the comparative study of
suspension helical coil spring with different materials using finite element
analysis. They create the shock absorber model in Creo Parametric 2.0 and
structural analysis of the same is done using ANSYS 17.0. The comparative
study shows the optimum material to be used for the spring by proper analysis
of the deflection and stresses of the helical spring. They used four different
material of spring are Chrome vanadium, Hard drawn spring wire, steel, Oil
tempered carbon steel and Stainless steel. After the analysis the chrome
vanadium stands out to be efficient material for spring especially at higher
loads.

MacArthur, L. Stewart [10] In this paper they determine the maximum torsion
stress, fatigue life, natural frequency and load loss due to stress relaxation of
helical compression spring. The intent of this paper was to make a useful
contribution to the published works for evaluating round wire helical
compression springs. They used FEA software to construct a structural model of
a helical compression spring to simulate its full range of compression. The aim
of these researchers was to replace steel with a viable composite material. In
this type of materials resulted in a reduction in stress and weight, but an
increase in displacement. They used an innovative methodology for
constructing a virtual prototype of a helical compression spring.

P.R. Jadhav et al. [11] This paper deals with analysis of dual suspension by
using FE approach and validated with analytical with varying speed. In this
research helical spring related to the light vehicle suspension system under the
effect of a uniform loading has been studied and finite element analysis has
been compared with analytical solutions. They compared the analysis results to
determine stress and deflection at various speeds for carbon steel material. The
model of dual suspension motor vehicle that can vibrate in the vertical direction
while traveling over a rough road. The results are elaborated in an earlier
chapter the brief discussion and conclusion is present as follows. The deflection
is Maximum in between the 3km/hrs to 10km/hrs and further reduces as speed
increases stress is Maximum in between the 3km/hrs to 10km/hrs and further
reduces as speed increases.
 PROBLEM STATEMENT

Conventional design of helical coil suspension is heavy weight and low on

performance in terms of strain energy absorption characteristic and fatigue life.
Therefore, it is essential to reduce weight of helical coil suspension to improve
fuel efficiency and fatigue life. To fulfil these requirements, it becomes
imperative to search for new materials and designs for this application

OBJECTIVE

1> CAD modelling of base design of helical coil suspension of CBZ extreme
using Creo 2.0 software
2> Static structural analysis, fatigue life analysis on base design using
ANSYS 19 software
3> Making design changes in cross section of coil and repeating step 2
Changing material of helical coil suspension to metal matrix composites
and performing static structural and fatigue life analysis using ANSYS 19
software.
4> Comparative analysis on basis of safety factor and fatigue life parameters
5> Cost and weight comparison for different designs and materials used.
 METHODOLOGY
The solution for the problem is performed in three stages - Theoretical Analysis,
Creating a Solid Model, Finite Element Analysis.

A. Creating a Solid Model A Three-Dimensional solid model of helical coil

suspension is created on the computer using CREO 2.0, PTC, USA. This 3D
Model is exported to ANSYS 14 for performing Finite Element Analysis.

B. Finite Element Analysis There are three main steps, namely: pre-
processing, solution and post processing. In pre-processing (model definition)
includes: define the geometric domain of the problem, the element type(s) to be
used, the material properties of the elements, the geometric properties of the
elements (length, area, and the like), the element connectivity (mesh the model),
the physical constraints (boundary conditions) and the loadings. In solution
phase, the governing algebraic equations in matrix form are assembled and the
unknown values of the primary field variable(s) are computed. The computed
results are then used by back substitution to determine additional, derived
variables, such as reaction forces, element stresses and heat flow. Actually, the
features in this step such as matrix manipulation, numerical integration and
equation solving are carried out automatically by commercial software. In post
processing, the analysis and evaluation of the result is conducted in this step.

C. Analytical validation Analytical validation is performed using deflection and

bending stress equation for laminated springs.
C. Design and Material Optimization: Once the results are validated with
analytical methods, subsequent design changes and material changes are made
with analysed using ANSYS 19 software.

METHODOLOGY FLOW CHART

CAD modelling of base design helical coil suspension

Importing CAD model in ANSYS 19

Static structural and fatigue life analysis using ANSYS 19

Changing cross section of helical coil suspension and repeating analysis

Changing material of helical coil suspension

Comparative analysis on the basis of parameters

like von-mises stress, deformation, fatigue life

Conclusion
 EXPECTED OUTCOME
1> Von mises stress
2> Principal stress
3> Deformation
4> Safety factor
5> Fatigue life
REFERENCES
[1] Dakhore M. & Bhushan Bissa et.al. “Failure analysis of helical suspension spring Using F.E.A.”, International journal Mgnt & research,
ISSN – 2320-0073, June 2013.

[2] Md. Mustak & m. Madhavi et.al. “Development of high strength helical coiled spring Using carbon pre-peg epoxy-based composite”,
Indian journal science 2005, ISSN- 2250-0138, 2013.

[3] Aamir A. Waghade, Gaurav V. Bansod et. al.” Experimental & harmonic Analysis of helical suspension spring”, Discovery May 2014.

[4] Mehdi Bakhshesh et. al. “Optimization of Steel Helical Spring by Composite Spring”, International journal of multidisciplinary Science
and Engineering, ISSN- 2045-7057, June 2012.

[5] Achyut P. Banginwar et. al. “Design and analysis of shock absorber using FEA tool”, International Journal of Engineering Research and
Development, ISSN-2278-067X, February 2014.

[6] P.S.Valsange,Design of Helical Coil Compression Spring” A Review, International Journal of Engineering Research and Applications,
ISSN: 2248-9622.

[7] Vijayeshwar BV, Preetham B,M, Bhaskar U (2017), “Static Analysis of Helical Compression Spring”, International Advanced Research
Journal of Science, Engineering and Technology, May 2017, Volume 4, Issue 7, pp 94-98.

[8] N. Sai Kumar, R.Vijay Prakash (2016), “Design and Analysis of Spring Suspension System”, International Journal of Professional
Engineering Studies, November 2016, Volume 7, Issue 4, pp 315-321.

[9] Suraj R. Bhosle, Shubham R. Ugle, Dr. Dhananjay R. Dolas (2017),“Comparative Analysis of Suspension System Coil Spring Using
FEA”, International Journal of Interdisciplinary Research (IJIR), 2017, Volume 1, Issue 1, pp 757-761.

[10] MacArthur, L. Stewart (2014), “A Computational Approach for Evaluating Helical Compression Springs”, International Journal of
Research In Engineering and Technology, December 2014, Volume 3, Issue 12, pp 224-229.

[11] P.R. Jadhav, N.P. Doshi, U.D. Gulhane (2014), “Analysis of Helical Spring in Dual suspension System Used in Motorcycle”,
International Journal of Advanced Engineering Research and Studies, October 2014, Volume 2, Issue 10, pp 117-121.