UNIT I VEHICLE

FRAME AND
SUSPENSION
AT6602 - AUTOMOTIVE CHASSIS
COMPONENTS DESIGN
 Introduction
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.
 Applications of Springs
1.To cushion, absorb or control energy due to either
shock or vibration as in car springs, railway
buffers, air-craft landing gears, shock absorbers
and vibration dampers.
2.To apply forces, as in brakes, clutches and spring-loaded
valves.
3.To control motion by maintaining contact between
two elements as in cams and followers.
4. To measure forces, as in spring balances and
engine indicators.
5. To store energy, as in watches, toys, etc.
 The Function(s) of Springs
Most fundamentally: to STORE ENERGY

Many springs can also: push

pull
twist
 Some
F
Review linear springs: k=F/y

k dF
nonlinear springs: k  dy

y Parallel
Series
1 1 1 1
  
k total k1 k 2 k3 ktotal=k1+k2+k3
 Types of Springs
Helical:

Compression

Extension
Torsion
 More Springs
Washer Springs:

Power springs:
Beams:
 Laminated or leaf
springs
The laminated or leaf spring (also
known as flat spring or carriage spring)
consists of a number of flat plates
(known as leaves) of varying lengths
held together by means of clamps and
bolts.
Laminated or leaf
springs
Laminated or leaf springs.
 Materials for Leaf Springs
1.For automobiles : 50 Cr 1, 50 Cr 1 V 23, and 55 Si 2
Mn 90 all used in hardened and
tempered state.
2.For rail road springs : C 55 (water-hardened), C 75
(oil-hardened), 40 Si 2 Mn 90 (water hardened)
and 55 Si 2 Mn 90 (oil-hardened).
3.The physical properties of some of these materials are
given in the following table. All
values are for oil quenched condition and for single heat
only.
Physical properties of materials
commonly used for leaf
springs.
Design of Leaf
Spring
Flat spring or cantilever spring
 STRESS AND DEFLECTION
Maximum stress on spring:-
6∗W∗L
o =
b∗t2
Maximum deflection
W∗L3 for a cantilever
δ b∗t3 Where I =
= 1
4∗W∗L3 6∗W2∗
3∗E∗I Lb∗t
=
2

δ 2∗o3∗E∗(b∗t )/1
3
∗2
= 3∗∗
2
o=
 Cont…
Simply supported beam type
 STRESS AND DEFLECTION
Maximum stress on spring:-
6∗W∗L
o =
b∗t2
Maximum deflection
W1∗L1for a cantilever
δ = 3 Where W1=
48∗E
2W∗(2L) ∗I 2W
= 3 b∗t L1 =
48∗E∗ 12
3
2*L
b∗t 6∗W ∗
I = 312 ando= Lb∗t
2

4∗w∗3
δ
= ∗b∗3
If the plate of cantilever is cut into a series of n strips of
width b and these are placed as shown
6∗W ∗ 4∗w∗L3
o L and
= n∗b∗t2 δ = n∗2∗o ∗L23 =
E∗b∗t 3∗o ∗n∗b∗
E∗t Where W = t2
6∗
L

This relations give the stress and deflection of a leaf spring

of uniform cross-section.
 Laminated leaf spring.
If a triangular plate is used as shown in Fig.(a), the stress will
be uniform throughout. If this triangular plate is cut into strips
of uniform width and placed one below the other, as shown in
Fig. (b) to form a graduated or laminated leaf spring.
 6∗W∗L
o= n∗b∗t
2

and 6∗W∗L3 o ∗L
δ 2
= n∗E∗b∗t3 =
E∗t
where n = Number of graduated leaves.
Semi-elliptical leaf
spring.
Stress in the graduated leaves,
12∗W ∗
oG = L
b∗t2
( 2ng+3nf)
Stress in the full lengthleaves,
18∗W ∗
o F=
b∗tL
2

( 2ng+3nf)
The deflection in full length and graduated leaves is given
by equation

δ = 3E∗t where ng = No.graduated

nofF∗L
2 = No.
2
full length leaves,
leaves,
12∗W∗L3
δ
E∗b∗t3
= ( 2ng+3nf)
 IMPORTANT DERIVATION
Consider that under maximum load conditions, the
stress in all the leaves is equal. Then at maximum load,
the total deflection of the graduated leaves will exceed
the deflection of the full length leaves by an amount
equal to the initial gap C.
δ G = δF + C
∴ C = δG -δF
2∗W∗L3
C= n∗E∗b∗t3
The load on the clip bolts (Wb)
2∗W∗( 2ng ∗ f
Wb nn
)∗( 2ng+3nf
= )
 Cont…
The final stress in spring leaves,

6∗W∗L
o= n∗b∗t …(Substituting n = nF + nG )
2

Notes :
1.The final stress in the leaves is also equal to the
stress in graduated leaves due to the applied load
plus the initial stress.
2.The deflection in the spring due to the applied
load is same as without initial stress.
 Length of Leaf Spring Leaves
Length of master leaf = 2 L1 + π (d + t) × 2
Where d = Inside diameter of eye, and
t = Thickness of master leaf.
Effective length of the spring,
2L = 2 L1 – l ...(When band is used)
2L = 2 L1 – 2/3*l ... (When U-bolts are
Let used)
2 L1 = Length of span or overall length of the spring,
l = Width of band or distance between centers of U-bolts. It is
the
ineffective length of the spring,
n = nF + n G
 Cont…
Length of smallest leaf = Effective
n–1
length
+
Ineffective length

Effective length
Length of next leaf = n–1 *2 +
Ineffective length
Similarly, length of (n – 1)thleaf,

Effective length
n–1 *(n – 1) + Ineffective length
The nth leaf will be the master leaf and it is of full
length. Since the master leaf has eyes on both Sides.
The approximate relation between the radius of curvature (R)
and the camber (y) of the spring
is given by

R = (L1)2 / 2y
The exact relation is given by

y (2R + y) = (L1)2
where L1 = Half span of the spring.
Note : The maximum deflection ( δ ) of the spring is equal to
camber (y) of the spring.
Problems
1.Design a leaf spring for the following
specifications : Total load = 140 kN ;
Number of springs supporting the load = 4 ;
Maximum number of leaves = 10;
Span of the spring = 1000 mm; Permissible deflection = 80 mm.
Take Young’s modulus, E = 200 kN/mm2 and allowable stress in
spring material as 600 MPa.
Given
Total load Wt= 140 kN ; No. of springs = 4; n = 10;
δ = 80 mm
2L = 1000 mm or L = 500 mm ;
E = 200 kN/mm2 = 200 × 103 N/mm2 ;
o = 600 MPa = 600 σ/mm 2
solution
We know that load on each spring,
2W = Wt/ No. of springs
2W = 140/4 = 35KN
W = 17.5KN = 17500N
To find t and b
6∗W∗L
bending stress is o= n∗b∗t
2
6∗17500∗500
600 = n ∗ b ∗ t 2 = 87.5 * 103 …..(1)
n∗b∗t
2
6∗W∗L3
deflection of the spring is δ = n∗E∗b∗t3
6∗17500∗500
80 = 3 n ∗ b ∗ t3 = 0.82 * 106
n∗E∗b∗t
3 …..(2)
Dividing equation (2) by equation (1), we
have
 t = 9.37 say 10 mm
from equation (1),
b = 87.5mm
from equation (2),
b
= 82mm
Taking larger of the two values, we
have width of leaves,
b = 87.5 say 90 mm.
2.A truck spring has 12 number of leaves, two of which are
full length leaves. The spring supports are 1.05 m apart and
the central band is 85 mm wide. The central load is to be
5.4 kN with a permissible stress of 280 MPa. Determine
the thickness and width of the steel spring leaves. The ratio
of the total depth to the width of the spring is 3. Also
determine the deflection of the spring.
Given
n = 12 ; nF = 2 ; 2L1 = 1.05 m = 1050 mm ;
l = 85 mm ; (n*t) / b = 3
2W = 5.4 kN = 5400 N or W = 2700 N ;
oF 280 MPa = 280 N/mm2
solution

Determine the Deflection of the spring

12∗W∗L
δ 3
E∗b∗t3
= ( 2ng
To find t+=
3nThickness
f) of the leaves, and b = Width of
the leaves.
n∗t given
b =3

b = n∗3
t
= 4*t where n = 12
The effective length of the spring,
2L = 2L1 – l = 1050 – 85 = 965 mm
∴ L = 965 / 2 = 482.5 mm
number of graduated
leaves,
Assuming that the leaves are not initially stressed, therefore
maximum stress or bending stress for full length leaves
(oF),
18∗W ∗
oF = L
b∗t2
( 18∗2
2ng+3700∗4
nf)
280= 482.5
t∗t2 ( 2∗10+3∗2)
t = 9.3 say 10mm
b = 4t = 4*10 = 40mm
Deflection of the spring
Taking E = 210 × 103 N/mm2
δ=
16.7mm
3. A locomotive semi-elliptical laminated spring has an
overall length of 1 m and sustains a load of 70 kN at its
center. The spring has 3 full length leaves and 15 graduated
leaves with a central band of 100 mm width. All the leaves
are to be stressed to 400 MPa, when fully loaded. The
ratio of the total spring depth to that of width is 2.
E = 210 kN/mm2. Determine :
1. The thickness and width of the leaves.
2.The initial gap that should be provided between the full
length and graduated leaves before
the band load is applied.
3.The load exerted on the band after the spring is
assembled.
Given
2L1 = 1 m = 1000 mm ;
2W = 70 kN or W = 35 kN = 35 × 103 N ;
nF = 3 ; nG = 15 ; l = 100 mm ;
o = 400 MPa = 400 N/mm2 ;
E = 210 kN/mm2= 210 × 103 N/mm2
Solution
To find thickness (t) and width (b) of
leaves
6∗W∗L ………(1)
o= n∗b∗t
2
All the leaves are equally stressed,
The total number of leaves,
n = nF + nG = 3 + 15 = 18
Ratio of the total spring depth (n × t) and width of leaves
n∗t
b
= 2 given

b = n∗t
3
= 9*t where n = 18
The effective length of the spring,
2L = 2L1 – l = 1000 – 100 = 900 mm
∴ L = 900 / 2 = 450 mm
Sub. L,n,b, o and W value in equ. No
(1) t = 11.34 say 12mm
b = 9*12 = 108mm
2. Initial gap (C)
w.k.t the initial gap (C) that should be provided between
the full length and graduated leaves before the band
load is applied, is given by
2∗W∗L3
C= n∗E∗b∗t3
C = 9.04mm
3. Load exerted on the band after the spring is
assembled
w.k.t the load exerted on the band after the spring is
assembled,
2∗W∗( 2ng ∗ n
Wb )n∗( 2ng+3nff
= )
Wb = 4487 N
4.A semi-elliptical laminated vehicle spring to carry a load of
6000 N is to consist of seven leaves 65 mm wide, two of the
leaves extending the full length of the spring. The spring is to
be 1.1 m in length and attached to the axle by two U-bolts 80
mm apart. The bolts hold the central portion of the spring so
rigidly that they may be considered equivalent to a band
having a width equal to the distance between the bolts.
Assume a design stress for spring material as 350 MPa.
Determine :
1. Thickness of leaves, 2. Deflection of spring,
3. Length of leaves, and 4. Radius to which leaves should
be initially bent.
Sketch the semi-elliptical leaf-spring arrangement.
The standard thickness of leaves are : 5, 6, 6.5, 7, 7.5, 8, 9,
10, 11 etc. in mm.
Given
2W = 6000 N or W = 3000 N ; n = 7 ; b = 65 mm ; nF = 2 ;
2L1 = 1.1 m = 1100 mm or L1= 550 mm ; l = 80 mm ;
o = 350 MPa = 350 N/mm2
Sol:
1. Thickness of leaves (t)
Assuming that the leaves are not initially stressed, the
maximum stress oF
18∗W ∗
o F = 2L i.eoF = o
b∗t
w.k.t (the
2nGeffective
+3nF) length
of the spring,
2L = 2L1 – l = 1100 – 80 = 1020 mm
∴ L = 1020 / 2 = 510 mm
and number of graduated leaves,
n G = n – n F= 7 – 2 = 5
18∗3000∗51
350 = 0∗t2
65
( 2∗5+3∗2)
t = 8.7 say 9mm
2. Deflection of spring
12∗W∗L
δ 3
E∗b∗t3
= ( 2nG1+2
3∗n
5F
0)
00∗510
3 take E =210∗
= 210∗103∗65∗93
103N/mm2
δ (=230mm
∗5+3∗2)
30 (2R – 30) = (550)2

R =5056.5mm Ans
 Design of coil spring
Terms used in Compression Springs

Solid length
Solid length of the spring,
LS = n'.d
where n' = Total number of coils, and
d = Diameter of the wire.
2. Free lengt
Free length of the spring,
LF = Solid length + Maximum compression + Clearance
between
adjacent coils (or clash
allowance)
= n'.d + δmax + 0.15 δmax
The following relation may also be used to find the free
length of the spring, i.e.
LF = n'.d + δmax + (n' – 1) × 1 mm
In this expression, the clearance between the two adjacent
coils is taken as 1 mm.
3. Spring index
Spring index, C = D / d
where D = Mean diameter of the coil, and
d = Diameter of the wire.
4. Spring rate.
The spring rate (or stiffness or spring constant) is
defined as the load required per unit deflection of the
spring.
Mathematically,
Spring rate, k = W / δ
where W = Load, and
δ = Deflection of the spring.
5. Pitch.
The pitch of the coil is defined as the axial distance between
adjacent coils in uncompressed state. Mathematically,

Pitch of the coil, p =Freen′length

–1
The pitch of the coil may also be obtained by using the
following relation, i.e.
Pitch of the coil, L −LS
p = n′F – 1 + d
where L= Free length of the spring,
Ls= Solid length of the spring,
n' = Total number of coils, and
d = Diameter of the wire.
LF = n.d+δmax
Stresses in Helical Springs of
Circular Wire
Let,
D = Mean diameter of the spring coil,
d = Diameter of the spring wire,
n = Number of active coils,
G = Modulus of rigidity for the spring material,
73575*106 Pa, for automobile springs
W = Axial load on the spring,
ı = Maximum shear stress induced in the wire,
C = Spring index = D/d,
p = Pitch of the coils, and
δ = Deflection of the spring, as a result of an axial
load
w.k.t the twisting moment,
D π
T = W*2 = 16*ı1*d 3
 8∗W∗D
ı 1 = π∗d3 or π∗D2 ∗
G∗D∗δ
Neglecting the effect of curvature
maximum shear stress induced in the wire (ı),
8∗W∗D
ı = KS * π∗d3
where 1
K = Shear stress factor = 1+ 2C
S

From the above equation,

1
ı =
π ∗d 3
*{1+2C }
8∗W∗D
Considering the effect of curvature
maximum shear stress induced in the wire (ı),
8∗W∗
ı = K*
π ∗d 2
Where 4€−1
K = 4€
Note: −4

The Wahl’s stress factor (K) may be considered as

composed of two sub-factors, KSand KC, such that
K = KS× KC
where KS= Stress factor due to shear, and
KC= Stress concentration factor due
to curvature.
 Deflection of Helical
Springs of Circular Wire
8∗W∗D3∗n 8∗W∗€3∗n π∗D2 ∗τ∗n
δ= = or
G∗d G∗ G∗
4
d where d

C = D/d

stiffness
w of theG∗spring or spring rate,
=
G∗d 4
=
δ 8∗D ∗n 8∗€ ∗n
3
d =constant
3
1. A helical spring is made from a wire of 6 mm
diameter and has outside diameter of 75 mm. If the
permissible shear stress is 350 MPa and modulus of
rigidity 84 kN/mm2, find the axial load which the spring
can carry and the deflection per active turn.
Given
d = 6 mm ; Do = 75 mm ; ı = 350 MPa = 350 N/mm2 ;
G = 84 kN/mm2 = 84 × 103 N/mm2
Sol:
w.k.t mean diameter of the spring,
D = Do – d = 75 – 6 = 69 mm
∴ Spring index, C =D/d
C = 11.5
2.Design a helical compression spring for a maximum
load of 1000 N for a deflection of 25 mm using the
value of spring index as 5. The maximum permissible
shear stress for spring wire is 420 MPa and modulus of
rigidity is 84 kN/mm2.
4€−1
Take Wahl’s factor, K = 4€
; where C = Spring index.
Given −4

W = 1000 σ ; δ = 25 mm ; C = D/d = 5 ;
ı = 420 MPa = 420 N/mm2;
G = 84 kN/mm2 = 84 × 103N/mm2
Solution
1.To find mean diameter (D)
We know that Wahl’s stress factor,
4€−1
K = 4€−4
= 1.31
maximum shear stress induced in the wire (ı),
8∗W∗
ı = K* π∗d2 ….(1)
Sub.ı, K,C,W values in equ. No (1) and find d
d = 6.3mm
∴ Mean diameter of the spring coil,
D = C.d = 5 d = 5 × 6.3 = 31.5 mm.
and outer diameter of the spring coil,
Do = D + d = 31.5 + 6.3
= 37.8
2. Number of turns of the coils
8∗W∗€3∗
deflection of the spring n G∗ ….(2)
δ=
Sub. The given values in equ. No
d (2) and find n
8∗1000∗53∗n
25 = 84 × 103∗6.3
n = 13.23 say 14
For squared and ground ends, the total number of turns,
n' = n + 2 = 14 + 2 = 16
3. Free length of the spring
We know that free length of the spring
= n'.d + δ + 0.15 δ = 16× 6.3+ 25 + 0.15 × 25
= 129.55mm
4. Pitch of the coil
We know that pitch of the coil

Free length
Pitch of the coil, p = n′ – 1
p = 8.636
3.A safety valve of 60 mm diameter is to blow off at a
pressure of 1.2 N/mm2. It is held on its seat by a close
coiled helical spring. The maximum lift of the valve is
10 mm. Design a suitable compression spring of spring
index 5 and providing an initial compression of 35
mm. The maximum shear stress in the material of the
wire is limited to 500 MPa. The modulus of rigidity
for the spring material is 80 kN/mm2.
Calculate : 1. Diameter of the spring wire,
2.Mean coil diameter,
3.Number of active turns, and
4.Pitch of the coil.
Take Wahl’s factor, K = 44€−4
€−1 0
+ .615; where C = Spring
index.
Given :
Valve dia. = 60 mm ; Max. pressure = 1.2 N/mm2;
δ2= 10 mm ; C = 5 ;δ1= 35 mm ;
ı = 500 MPa = 500 N/mm2 ;
G = 80 kN/mm2= 80 × 103N/mm2
Solution
(1)To find Diameter of the spring wire(d)
maximum shear stress induced in the wire (ı),
8∗W∗
ı = K* π∗d2 ……..(1)
4€−1
Take K = 4€
= 1.31 given C =5
Find ‘W’ −4
W1= Area of the valve × Max. pressure
= 4*d *p2 = 4*60 *1.2
2 W1 = 3393N

maximum compression of the spring,

δmax =δ1+ δ2= 35 + 10 = 45 mm
Since a load of 3394 N keeps the valve on its seat by
providing initial compression of 35 mm, therefore the
maximum load on the spring when the valve is oepn
(i.e. for maximum compression of 45 mm),
W = 33 3
93
*45 W = 4363N
;Sub. ı,W,K,C
5 value in equ. σo (1) and find ‘d’
d = 12.06 say 12.7mm
2. Mean coil diameter(D)
Let D = Mean coil diameter.
w.k.t the spring index,C= D/d or
D = C.d = 5 × 12.7
D = 63.5 mm
3. Number of active turns (n)
w.k.t max. deflection of the spring

δ= …….(2)
G∗
8∗W∗€ 3
∗n
Sub. Thed given values in equ. No (2) and find ‘n’
n = 10.5 say 11
Taking the ends of the coil as squared and ground, the
total number of turns,
n' = n + 2 = 11 + 2 = 13
4. Pitch of the coil (p)
LF= n' *d + δmax
LF = 216.85mm
Pitch of the coil,
p=
Free length
n′ – 1
p=
216.85
13 – 1
p =
18.1mm
 4.A typical coil suspension spring has 10 effective coil
of a mean diameter 125mm and made out of a wires of
diameter 15mm. The spring is designed to a carry a
maximum load of 3531.6N. Calculate the sheer stress
and deflection under the above loading. If a maximum
sheer stress of 637650kpa is allowable in a material,
then what is possible clearance in the spring? Take the
value of G =73575*103kpa.
Given:
n= 10, D = 125mm, d = 15mm, W =
3531.6N,
ıG == 637650kpa
73575 *103;kpa= 73575N/mm2 =
73575MPa
Solution
w.k.t max. deflection of the spring
8∗W∗D3∗
δ = n G∗d
4
8∗3531.6∗1253∗1
=0
73575∗15
4
δ = 148.14mm
w.k.t sheer stress of the spring
G∗d∗
ı=
π∗D2 ∗
73575∗106∗0.015∗0.14
= 8

t = π∗0.1252 ∗10
332.74MPa
w.k.t max. sheer stress of the
spring
ı max= G∗d∗2max
π∗D ∗
To find max
π ∗D2 ∗ ∗ ı max
ma = G∗
x
d π∗1252 ∗10 ∗ 637650
=
73575 ∗103 ∗15
a = 283.6mm
A clearance (283.6 -148.14) = 135.46 say 136mm can
be allowed
A torsion bar suspension is to be designed to support a
maximum static load of 3433.5N at the end of lever arm
250mm long. The deflection of the lever above the
horizontal is to be 30° with a total angle of deflection of
90°. assuming a safe allowable stress of 784800kpa,
calculate the diameter of the torsion (b) the
bar effective length and the load rate.
Given
l = 250mm; fs = 784800kpa; α = 30°; θ = 90°
WS = 3433.5N
Equalized Stress inSpring
Leaves (Nipping)
The full length leaves is 50% greater than the stress in
the graduated leaves.