1. INTRODUCTION 1.

1 Introduction
A suspension system or shock absorber is a mechanical device designed to smooth out and dissipate kinetic energy. The shock absorbers function is to absorb or dissipate energy. In a vehicle, it reduces the effect of traveling over rough ground, leading to improve ride quality, and increase in comfort due to substantially reduced amplitude of disturbances. Basic safety and also traveling ease and comfort to get a cars motorist are usually equally influenced by the particular vehicles suspension method. Safety refers to the vehicles handling and braking capabilities. Shock absorbers are a critical part of a suspension system, connecting the vehicle to its wheels. Basically shock absorbers tend to be products which lessen a good behavioral instinct skilled with an automobile, as well as properly absorb the actual kinetic power. Almost all suspension systems consist of springs and dampers, which tend to limit the performance of a system due to their physical constraints. Suspension systems, comprising of springs and dampers are usually designed for passengers safety and do little to improve passenger comfort. One particular strategy to this can be the application of productive suspension devices, wherever highway circumstances are generally found employing detectors, plus the technique in a flash adapts on the placing. A shock absorber is a device which is designed to smooth out sudden impulse responses, and dissipate kinetic energy. Any moving object possesses kinetic energy, and if the object changes direction or is brought to rest, it may dissipate kinetic energy in the form of destructive forces within the object. The purpose of a shock absorber, within any moving object, is to dissolve the kinetic energy evenly while eliminating any decelerating force that may be destructive to the object. Shock absorbers are an important part of automobile and motorcycle suspensions, aircraft landing gear, and the supports for many industrial machines. Large shock absorbers have also been used in structural engineering to reduce the susceptibility of structures to earthquake damage. A transverse mounted shock absorber, helps keep railcars from swaying excessively from side to side and are important in passenger railroads systems because they prevent railcars from damaging station platforms. In a vehicle, it reduces the effect of traveling over rough ground, and leading to improved ride quality. Without shock absorbers, the vehicle
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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 typical shock absorber may simply comprise of a compression spring that is capable of absorbing energy. Commonly shock absorbers are known as dashpots, which is simply a fluid filled cylinder with an aperture through which fluid could escape under controlled conditions. The dashpot is the building block for pneumatic and hydraulic shock absorbers. These shock absorbers essentially consist of a cylinder, filled with air or fluid, with a sliding piston that moves to dissipate or absorb energy, and in these cases the energy is usually dissipated as heat.

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1.2 Objectives of the Project

Study the causes of bouncing problems of the vehicle. Compare the failure parts performance in terms of its yield strength between beryllium copper and spring steel. Springs in parallel combination is used further for a comfortable ride.

1.3 Scope of Study

The scope of study for this project includes: Applying structural and modal analysis on the shock absorber. Applying dynamic analysis on the shock absorber.

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2. LITERATURE SURVEY 2.1 Shock Absorber

The shock absorber is really a mechanized gadget made to lessen or even moist surprise behavioral instinct, as well as dissolve kinetic power. It's a kind of dashpot. The shock absorber function is to absorb or dissipate energy. One design consideration, when designing or choosing a shock absorber, is where that energy will go. In many dashpots, power is actually transformed into warmth within the viscous liquid. Within hydraulic cylinders, the actual hydraulic liquid gets hotter, during atmosphere cylinders, the actual heat is generally worn out towards the environment. In other types of dashpots, such as electromagnetic types, the dissipated energy can be stored and used later. In general terms, shock absorbers help cushion vehicles on uneven roads. Shock absorbers tend to be an essential a part of car as well as motorbike suspensions, plane getting equipment, and also the facilities for a lot of commercial devices. Big shock absorbers are also utilized in structural architectural to lessen the actual susceptibility associated with buildings in order to earthquake harm as well as resonance. The transverse installed shock absorber, known as the yaw damper, helps maintain railcars through swaying too much laterally and therefore are essential within traveler railroads, commuter train as well as quick transit techniques simply because they avoid railcars through harmful train station systems. Inside a vehicle, shock absorbers slow up the effect associated with travelling more than rough floor, leading in order to improve trip quality as well as increase within comfort. While surprise absorbers serve the objective of limiting extreme suspension motion, their meant sole purpose would be to dampen springtime oscillations. Shock absorbers make use of valve associated with oil as well as gasses to soak up excess energy in the springs. Spring prices are chosen through the manufacturer in line with the weight from the vehicle, packed and unloaded. Some individuals use shocks to change spring prices but this isn't the proper use. Together with hysteresis within the tire by itself, they dampen the power stored within the motion from the unsparing weight down and up. Effective steering wheel bounce damping may need tuning shocks for an optimal opposition. Spring-based surprise absorbers generally use coils springs or even leaf comes, though torsion bars are utilized in torsion shocks too. Ideal comes
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alone, nevertheless, are not really shock absorbers, as come only store and don't dissipate or even absorb power. Vehicles usually employ each hydraulic surprise absorbers as well as springs or even torsion pubs. In this particular combination, "shock absorber" pertains specifically towards the hydraulic piston which absorbs as well as dissipates vibration.

2.2 Main components of Shock Absorber Shock absorber has three main components to make it function well. They are damper, spring and bushing. These all three part are playing an important role to work together and absorb the impact or bouncing. 2.2.1 Damper Damper shock absorber or simply damper is device that is designed for providing absorption of shock and smooth deceleration in linear motion applications. The dampers can be either mechanical or rely on a fluid. Dampers like other shock absorber absorb shock by controlling the flow of the fluid from outer to inner chamber of a cylinder during piston actuation. The damper shock absorbers

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can be adjusted to different road conditions and provides good balance to the vehicles. 2.2.2 Spring Spring shock absorber as the name suggests is used to absorb the jerks or bumps by using coil spring. The spring shock absorber is given stiffer character by tightening the spring. The center of the spring shock absorber usually contains rebound dampening unit. As the shock absorber changes the length the flow fluid inside the shock absorber starts. Springs length is usually controlled by turning the disc at the bottom of the spring on the threads. The shorter spring length increases the preload, making the rear wheel more resistant to upward motion. The dampening is both controlled and adjusted in the spring shock absorber by controlling the fluid reservoir. If the dampening is increased the motion of the shock is slowed down. The spring type of shock absorbers are usually utilized for protecting the delicate mechanisms, like instruments, from direct impact or loads that are applied instantaneously. These types of springs are often made of rubber or similar elastic material. The springs that are used in different spring based shock absorbers are coil springs or leaf springs. In tensional shocks, torsion bars can be used. In most of the vehicles, springs or torsion bars as well as hydraulic shock absorbers are used. 2.2.3 Bushing A bushing or rubber bushing is a type of vibration isolator. It provides an interface between two parts, damping the energy transmitted through the bushing. A common application is in vehicle suspension systems, where a bushing made of rubber (or, more often, synthetic rubber or polyurethane) separates the faces of two metal objects while allowing a certain amount of movement. This movement allows the suspension parts to move freely, for example, when traveling over a large bump, while minimizing transmission of noise and small vibrations through to the chassis of the vehicle. A rubber bushing may also be described as a flexible mounting or anti vibration mounting.

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2.3 Dynamics of shock absorber 2.3.1 Response due to harmonic excitation of support Consider the mass-spring-dashpot system of Figure 2.3.1. The spring and dashpot are in parallel with one end of each connected to the mass and the other end of each connected to a moveable support. Let y (t) denote the known displacement of the support and let x (t) denote the absolute displacement of the mass.

FIGURE 2.3.1 (a) FIGURE 2.3.1 (b) (a) Block is connected through parallel combination of spring and viscous damper to a moveable support. (b) FBDs at an arbitrary instant. Spring and viscous damper forces include effects of base motion.

Application of Newtons law to the free-body diagrams of Figure yields .. (1) .(2)

(3) As the displacement of the mass relative to the displacement of its support. Above equation (2) is rewritten using z as the dependent variable .(4 ) Dividing Equations (2) by (4) by m yields

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.. (5) .... (6) If the base displacement is given by a single-frequency harmonic of the form y (t) =Y sin t Then Equations (5) and (6) become ..(7) ..(8) Equation (8) shows that a mass-spring-dashpot system subject to harmonic base motion is yet another example in which the magnitude of a harmonic excitation is proportional to the square of its frequency. (9) (10) When Equations (9) and (10) are substituted into Equation (3) the absolute displacement becomes . (11) Using the trigonometric relationship for the sine of the difference of two angles, it is possible to express Equation (11) in the form . (12) . (13) (14)

. (15)
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X/Y is the amplitude of the absolute displacement of the mass to the amplitude of displacement of the base. Multiplying the numerator and denominator by 2 leads to

..(16)

Equation (15) is plotted in Figure The following are noted about

..(17)

GRAPH - 1

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(18) 4. The maximum T(r, ) corresponding to the frequency ratio of Equation (18)

(19)

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3. METHODOLOGY 3.1 Springs in parallel

FIGURE 3.1 When two springs are connected in parallel, both springs will deflect by same amount and the load is shared between two springs. It is observed from the figure, when force F1 is acting on spring of stiffness s1, spring deflects by an amount . When force F2 (greater than F1) is acting on spring on stiffness s2, spring deflects by same amount . When force F1+F2 is acting on both springs, equivalent spring deflects by same amount . So spring in spring or concentric springs has the following advantages: Since there are two springs, the load carrying capacity is increased and heavy load can be transmitted in a restricted space. In concentric spring, the operation of the mechanism continues even if one of the springs breaks.

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3.2 Design Calculations of Helical springs for Shock absorbers Mean diameter of a coil = D=60mm Diameter of wire d = 8mm Total no of coils n= 10 Height h = 185mm Outer diameter of spring coil Do= D +d =68mm No of active turns n = 8 Weight of bike = 125 Kgs Let weight of 1 person = 75 Kgs Weight of 2 persons = 150 Kgs Weight of bike + persons = 275 Kgs Rear suspension = 65% of W 65% of 275 = 165 Kgs Considering dynamic loads it will be double W = 330 Kgs = 3234 N For single shock absorber weight = w/2= 1617 N = W We Know that, compression of spring () = 8Wxc3xn Gxd = 8x1617x83x10 = 201.92 mm 41000x8 10 x 8 =80 mm

10x8+201.92+0.15x201.92=312.2 mm 1617/201.92=8 (312.2+80)/10=39.22 mm

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(0.97x8x1617x8)/ (3.14x82) =499.26 Mpa

312.2/60=5.2

Wcr = 8x 0.05 x 312.2 = 124.88 N

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4. INTRODUCTION TO CAD & NX 7.5 4.1. INTRODUCTION TO CAD 4.2. TECHNOLOGY OF CAD 4.3. PRODUCT DEVELOPMENT THROUGH CAD PROCESS 4.4. INTRODUCTION TO NX 7.5 4.5. SOLID GEOMETRIC MODELING

4.1 INTRODUCTION TO CAD

Computer Aided Design (CAD) is a technique in which man and machine are blended into problem solving team, intimately coupling the best characteristics of each. The result of this combination works better than either man or machine would work alone, and by using a multi discipline approach, it offers the advantages of integrated team work. The advances in Computer Science and Technology resulted in the emergence of very powerful hardware and software tool. It offers scope for use in the entire design process resulting in improvement in the quality of design. The advent of CAD as a field of specialization will help the engineer to acquire the knowledge and skills needed in the use of these tools in an efficient and effective way on the design process. Computer Aided Design is an interactive process, where the exchange of information between the designer and the computer is made as simple and effective as possible. Computer aided design encompasses a wide variety of computer based methodologies and tools for a spectrum of engineering activities planning, analysis, detailing, drafting, construction, manufacturing, monitoring, management, process control and maintenance. CAD is more concerned with the use of computer-based tools to support the entire life cycle of engineering system of design. The modern manufacturing environment can be characterized by the paradigm of delivering products of increasing variety, smaller batches and higher quality in the context of increasing global competition. Industries cannot survive worldwide competition unless they introduce new products with better quality, at lower costs and with shorter lead-time. There is intense international competition and decreased availability of skilled labor. With dramatic changes in computing power and wider availability of software tools for design and production, engineers
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are now using Computer Aided Design (CAD), Computer Aided Manufacturing (CAM) and Computer Aided Engineering (CAE) systems to automate their design and production processes. These technologies are now used every day for sorts of different engineering tasks. Below is a brief description of how CAD technology is being used during the product realization process.

4.1.1 PRODUCT REALIZATION PROCESS:

The product realization process can be roughly divided into two phases; design and manufacturing. The design process starts with identification of new customer needs and design variables to be improved, which are identified by the marketing personnel after getting feedback from the customers. Once the relevant design information is gathered, design specifications are formulated. A feasibility study is conducted with relevant design information and detailed design and analyses are performed. The detailed design includes design conceptualization, prospective product drawings, sketches and geometric modeling. Analysis includes stress analysis, interference checking, kinematics analysis, mass property calculations and tolerance analysis, and design optimization. The quality of the results obtained from these activities is directly related to the quality of the analysis and the tools used for conducting the analysis. This project is mainly concentrated on product design and its analysis only.

4.1.2 BRIEF HISTORY OF CAD

The roots of current CAD/CAM technologies go back to the beginning of civilization when engineers in ancient Egypt recognized graphics communication. Orthographic projection practiced today was invented around the 1800s. Therell development of CAD/CAM started in the 1950s. CAD/CAM went through four major phases of development in the last century. The 1950s was known as the era of interactive computer graphics. MITs Servo Mechanisms Laboratory demonstrated the concept of numerical control (NC) on milling machine. Development in this era was slowed down by the shortcomings of computers at the time. During the late 1950s the development of Automatically Programmed Tools (APT) began and General Motors explored the potential of interactive graphics. The 1960s was the most critical research period for interactive computer graphics. Ivan Sutherland developed a sketchpad system, which demonstrated the possibility of creating drawings and altercations of objects interactively on a cathode ray tube (CRT). The term CAD started to appear with the word design extending beyond basic drafting concepts. General Motors
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announced their DAC-1 system and Bell Technologies introduced the GRAPHIC 1 remote display system. During the 1970s, the research efforts of the previous decade in computer graphics had begun to be fruitful, and potential of interactive computer graphics in improving productivity was realized by industry, government and academia. The 1970s is characterized as the golden e ra for computer drafting and the beginning of ad hoc instrumental design applications. National Computer Graphics Association (NCGA) was formed and Initial Graphics Exchange Specification (IGES) was initiated. In the 1980s, new theories and algorithms evolved and integration of various elements of design and manufacturing was developed. The major research and development focus was to expand CAD/CAM systems beyond three-dimensional geometric designs and provide more engineering applications. The present day CAD/CAM development focuses on efficient and fast integration and automation of various elements of design and manufacturing along with the development of new algorithms. There are many commercial CAD/CAM packages available for direct usages that are user-friendly and very proficient. Below are some of the commercial packages in the present market. AutoCAD and Mechanical Desktop are some low-end CAD software systems, which are mainly used for 2D modeling and drawing. NX, Pro-E, CATIA and I-DEAS, DSS SOLID WORKS are high-end modeling and designing software systems that are costlier but more powerful. These software systems also have computer aided manufacturing and engineering analysis capabilities. ANSYS, ABAQUS, NASTRAN, Fluent and CFX are packages mainly used for analysis of structures and fluids. Different software are used for different proposes. For example, Fluent is used for fluids and ANSYS is used for structures. Alibre and Collab CAD are some of the latest CAD systems that focus on collaborative design, enabling multiple users of the software to collaborate on computer-aided design over the Internet.

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4.1.3. DEFINITION OF CAD/CAM/CAE Following are the definitions of some of the terms used in this tutorial. 4.1.3a.Computer Aided Design CAD CAD is technology concerned with using computer systems to assist in the creation, modification, analysis, and optimization of a design. Any computer program that embodies computer graphics and an application program facilitating engineering functions in design process can be classified as CAD software. The most basic role of CAD is to define the geometry of design a mechanical part, a product assembly, an architectural structure, an electronic circuit, a building layout, etc. The greatest benefits of CAD systems are that they can save considerable time and reduce errors caused by otherwise having to redefine the geometry of the design from scratch every time it is needed. 4.1.3b.Computer Aided Manufacturing CAM CAM technology involves computer systems that plan, manage, and control the manufacturing operations through computer interface with the plants production resources. One of the most important areas of CAM is numerical control (NC). This is the technique of using programmed instructions to control a machine tool, which cuts, mills, grinds, punches or turns raw stock into a finished part. Another significant CAM function is in the programming of robots. Process planning is also a target of computer automation. 4.1.3c.Computer Aided Engineering CAE CAE technology uses a computer system to analyze the functions of a CAD-created product, allowing designers to simulate and study how the product will behave so that the design can be refined and optimized. CAE tools are available for a number of different types of analyses. For example, kinematic analysis programs can be used to determine motion paths and linkage velocities in mechanisms. Dynamic analysis programs can be used to determine loads and displacements in complex assemblies such as automobiles. One of the most popular methods of analyses is using a Finite Element Method (FEM). This approach can be used to determine stress, deformation, heat transfer, magnetic field distribution, fluid flow, and other continuous field problems that are often too tough to solve with any other approach.

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4.2. Technology of CAD CAD technology makes use of drawings of parts and assemblies on computer files which can be further analyzed and optimized. The functional, ergonomic and aesthetic features of the product can be evaluated on the computers. This has been made possible through the use of the design workstations or CAD terminals and graphics and analytic software, which help the designer to interactively model and analyze object or component. CAD can be put to a variety of uses, some of which are listed below. 1. Create conceptual product model/models. 2. Editing or refining the model to improve aesthetic, ergonomics and performance, 3. Display the product in several colors to select color combination most appealing to customers, 4. Rotate and views the object from various sided and direction. 5. Create and display all inner details of the assembly. 6. Check for interference or clearance between mating parts in static and /or dynamic situations. 7. Analyze stress, static deflection and dynamic behavior for different mechanical and thermal loading configurations and carry out quickly any necessary design modifications to rectify deficiencies in design. 8. Study the product from various aspects such as material requirements, costs, value engineering manufacturing processes,
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standardization, simplification, weight reduction, service life, lubricants, servicing and maintenance aspects etc. 9. Prepare detailed component drawings giving full details of dimensions, tolerances, surface finish requirements, functional specification etc. 10. Prepare assembly drawing depicting the orientation of components, 11. Assembly procedures and requirements and incorporation, as required, such 12. Prepare exploded view of the assemblies. These views could be so oriented as to provide better visibility and improved comprehension of the design. Plot to print the picture/drawing stored in a computer file or the computer screen on different media. 13. Store the database of the object. Part of the drawing in a magnetic disc or tape for the retrieval at the later date for the use in some other design. 4.2.1. Modification of existing design The above description reveals that CAD technologies give the design engineer a powerful tool for graphical tasks .Modern CAD systems are based on interactive computer graphics communicates data and commands to the computer through the several input devices, to create an image or model on the computer screen by entering command to call and active the required software subroutines stored in the computer. In a 2-dimensional drafting system the images are constructed out of basic geometric elements or entities like points, lines, arcs, circles etc. These images can then be modified. Rotated, scaled or transformed in several ways depending upon the designers requirement.

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4.3. PRODUCT DEVELOPMENT THROUGH CAD PROCESS: The product begins with a need that is identified based on costumer and markets demands. The product goes through two main processes from the idea conceptualization to the finished product the design process and the manufacturing process. Product development through CAD product. Synthesis and analysis are the main sub processes that constitute the deign process. Synthesis is crucial to design an analysis. The philosophy, functionality and uniqueness of the product are all determined during the synthesis. The major financial commitment to turn the conceived product idea into reality is also made. Most of the information generated during the synthesis sod process is qualitative and consequently is hard to captured in a computer system expert and knowledge based systems have made a great deal of progress in this regard and the interested conceptual design of the prospective product. Typically, this design takes the form of a sketch or surrounding constrains. It is also employed during brainstorming discussions among various design terms and the presentation purpose. 4.4. Introduction to NX 7.5 NX is one of the worlds most advanced and tightly integrated CAD/CAM/CAE product development solutions. Spanning the entire range of product development, NX delivers immense value to enterprises of all sizes. It simplifies complex product designs, thus speeding up the process of introducing products to the market. The NX software integrates knowledge-based principles, industrial design, geometric modeling, advanced analysis, graphic simulation, and concurrent engineering. The software has powerful hybrid modeling capabilities by integrating constraint-based feature modeling and explicit geometric modeling. In addition to modeling standard geometry parts, it allows the user to design complex free-form shapes such as airfoils and manifolds. It also merges solid and surface modeling techniques into one powerful tool set.

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4.5. SOLID GEOMETRIC MODELING: A solid model of an object is a completed representation of the object. This model is capable of complex geometry data representation that is the art completely defined ,solid modeling techniques based on information ally complete, valid and unambiguous of object solid modelers store more information (geometry and topology) than wire frame modelers of surface (geometry only). Both wire frame and surface modelers are incapable of handling special address ability as well as verifying that the model is well framed or not. Solid models can be quickly created without having to define individual locations as with wire frames. Solid modeling produces accurate designs, provides complete three-dimensional improves the quality of the design, improves and has potential for functional automation and integration. The first step in working in NX is to log on to a workstation and start an NX session. After you start NX, you see the No Part interface. You can change defaults and preferences, open an existing part file, or create a new part file.

FIG4.5
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4.5.1. MODELLING OF SHOCK ABSORBER 1. Outer spring

FIGURE 4.5.1a

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2. Inner spring

FIGURE 4.5.1b

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3. Solid model of outer spring

FIGURE 4.5.1.c 4. Solid model of Inner spring

FIGURE 4.5.1d
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5. Cylinder

FIGURE 4.5.1e
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6. Solid model of cylinder

FIGURE 4.5.1f 7. Hat

FIGURE 4.5.1 g

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8. Rings and Rod

FIGURE 4.5.1 h

FIGURE 4.5.1 i
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FIGURE 4.5.1 J 9. Sequence of assembly

FIGURE 4.5.1K
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FIGURE 4.5.1 L

FIGURE 4.5.1 m
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10. Final model of shock absorber

FIGURE 4.5.1 n

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5. INTRODUCTION TO FEA
Finite Element Analysis (FEA) was first developed in 1943 by R. Courant, who utilized the Ritz method of numerical analysis and minimization of variational calculus to obtain approximate solutions to vibration systems. Shortly thereafter, a paper published in 1956 by M. J. Turner, R. W. Clough, H. C. Martin, and L. J. Topp established a broader definition of numerical analysis. The paper centered on the "stiffness and deflection of complex structures". By the early 70's, FEA was limited to expensive mainframe computers generally owned by the aeronautics, automotive, defense, and nuclear industries. Since the rapid decline in the cost of computers and 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 are used in industry: 2-D modeling, and 3-D modeling. While 2-D modeling conserves simplicity and allows the analysis to 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. Nonlinear 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 make a grid called a mesh. This mesh is programmed to contain the material and structural properties which define 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.
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This web of vectors is what carries the material properties to the object, creating many elements. A wide range of objective functions (variables within the system) are available for minimization or maximization: Mass, volume, temperature Strain energy, stress strain Force, displacement, velocity, acceleration Synthetic (User defined) There are multiple loading conditions which may be applied to a system. Some examples are shown: Point, pressure, thermal, gravity, and centrifugal static loads Thermal loads from solution of heat transfer analysis Enforced displacements Heat flux and convection Point, pressure and gravity dynamic loads Each FEA program may come with an element library, or one is constructed over time. Some sample elements are: Rod elements Beam elements Plate/Shell/Composite elements Shear panel Solid elements Spring elements Mass elements Rigid elements Viscous damping elements Many FEA programs also are equipped with the capability to use multiple materials within the structure such as: Isotropic, identical throughout Orthotropic, identical at 90 degrees General anisotropic, different throughout

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5.1. Types of Engineering Analysis:

Structural analysis consists of linear and non-linear models. Linear models use simple parameters and assume that the material is not plastically deformed. Non-linear models consist of stressing the material past its elastic capabilities. The stresses in the material then vary with the amount of deformation as in. Vibrational analysis is used to test a material against random vibrations, shock, and impact. Each of these incidences may act on the natural vibrational frequency of the material which, in turn, may cause resonance and subsequent failure. Fatigue analysis helps designers to predict the life of a material or structure by showing the effects of cyclic loading on the specimen. Such analysis can show the areas where crack propagation is most likely to occur. Failure due to fatigue may also show the damage tolerance of the material. Heat Transfer analysis models the conductivity or thermal fluid dynamics of the material or structure. This may consist of a steady-state or transient transfer. Steady-state transfer refers to constant thermo properties in the material that yield linear heat diffusion.

5.2. Results of Finite Element Analysis

FEA has become a solution to the task of predicting failure due to unknown stresses by showing problem areas in a material and allowing designers to see all of the theoretical stresses within. This method of product design and testing is far superior to the manufacturing costs which would accrue if each sample was actually built and tested. In practice, a finite element analysis usually consists of three principal steps: 1. Preprocessing: The user constructs a model of the part to be analyzed in which the geometry is divided into a number of discrete sub regions, or elements," connected at discrete points called nodes." Certain of these nodes will have fixed displacements, and others will have prescribed loads. These models can be extremely time consuming to prepare, and commercial codes vie with one another to have the most user-friendly graphical preprocessor" to assist in this rather tedious chore. Some of these preprocessors can overlay a mesh on a preexisting CAD file, so that finite element analysis can be done conveniently as part of the computerized drafting-and-design process.

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2. Analysis: The dataset prepared by the preprocessor is used as input to the finite element code itself, which constructs and solves a system of linear or nonlinear algebraic equations Kijuj = fi Where u and f are the displacements and externally applied 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 stress analyses. Commercial codes may have very large element libraries, with elements appropriate to a wide range of problem types. One of FEA's principal advantages is that many problem types can be addressed with the same code, merely by specifying the appropriate element types from the library. 3. Post processing: In the earlier days of finite element analysis, the user would pore through reams of numbers generated by the code, listing displacements and stresses at discrete positions within the model. It is easy to miss important trends and hot spots this way, and modern codes use graphical displays to assist in visualizing the results. A typical postprocessor display overlays colored contours representing stress levels on the model, showing a full field picture similar to that of photo elastic or moir experimental results.

5.3. INTRODUCTION TO ANSYS WORKBENCH

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. The software implements equations that govern the behavior of these elements and solves them all; creating a comprehensive explanation of how the system acts as a whole. These results then can be presented in tabulated, or graphical forms. This 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 their geometry, scale, or governing equations. ANSYS is the standard FEA teaching tool within the Mechanical Engineering Department at many colleges. ANSYS is also used in Civil and Electrical Engineering, as well as the Physics and Chemistry departments. ANSYS provides a cost-effective way to explore the performance of products or processes in a virtual environment. This type of product development is
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termed virtual prototyping. With virtual prototyping techniques, users can iterate various scenarios to optimize the product long before the manufacturing is started. This enables a reduction in the level of risk, and in the cost of ineffective designs. The multifaceted nature of ANSYS also provides a means to ensure that users are able to see the effect of a design on the whole behavior of the product, be it electromagnetic, thermal, mechanical etc. An overview of ANSYS WORK BENCH

FIGURE 5.3

5.4. Generic Steps to Solving any Problem in ANSYS:

Like solving any problem analytically, you need to define (1) your solution domain, (2) the physical model, (3) boundary conditions and (4) the physical properties. You then solve the problem and present the results. In numerical methods, the main difference is an extra step called mesh generation. This is the step that divides the complex model into small elements that become solvable in an otherwise too complex situation. Below describes the processes in terminology slightly more attune to the software.
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 Build Geometry Construct a two or three dimensional representation of the object to be modeled and tested using the work plane coordinate system within ANSYS. Define Material Properties Now that the part exists, define a library of the necessary materials that compose the object (or project) being modeled. This includes thermal and mechanical properties. Generate Mesh At this point ANSYS understands the makeup of the part. Now define how the modeled system should be broken down into finite pieces. Apply Loads Once the system is fully designed, the last task is to burden the system with constraints, such as physical loadings or boundary conditions. Obtain Solution This is actually a step, because ANSYS needs to understand within what state (steady state, transient etc.) the problem must be solved. Present the Results After the solution has been obtained, there are many ways to present ANSYS results, choose from many options such as tables, graphs, and contour plots.

5.5. Specific Capabilities of ANSYS:

5.5.1. Structural Structural analysis is probably the most common application of the finite element method as it implies bridges and buildings, naval, aeronautical, and mechanical structures such as ship hulls, aircraft bodies, and machine housings, as well as mechanical components such as pistons, machine parts, and tools. Static Analysis - Used to determine displacements, stresses, etc. under static loading conditions. ANSYS can compute both linear and nonlinear static analyses.
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Nonlinearities can include plasticity, stress stiffening, large deflection, large strain, hyper elasticity, contact surfaces, and creep. Transient Dynamic Analysis - Used to determine the response of a structure to arbitrarily time-varying loads. All nonlinearities mentioned under Static Analysis above are allowed. Buckling Analysis - Used to calculate the buckling loads and determine the buckling mode shape. Both linear (eigenvalue) buckling and nonlinear buckling analyses are possible. In addition to the above analysis types, several special-purpose features are available such as Fracture mechanics, Composite material analysis Fatigue, and Both p-Method and Beam analyses. 5.5.2. Thermal ANSYS is capable of both steady state and transient analysis of any solid with thermal boundary conditions. Steady-state thermal analyses calculate the effects of steady thermal loads on a system or component. Users often perform a steady-state analysis before doing a transient thermal analysis, to help establish initial conditions. A steady-state analysis also can be the last step of a transient thermal analysis; performed after all transient effects have diminished. ANSYS can be used to determine temperatures, thermal gradients, heat flow rates, and heat fluxes in an object that are caused by thermal loads that do not vary over time. Such loads include the following: Convection Radiation Heat flow rates Heat fluxes (heat flow per unit area) Heat generation rates (heat flow per unit volume) Constant temperature boundaries A steady-state thermal analysis may be either linear, with constant material properties; or nonlinear, with material properties that depend on temperature. The thermal properties of most material vary with temperature. This temperature dependency being appreciable, the analysis becomes nonlinear. Radiation boundary
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conditions also make the analysis nonlinear. Transient calculations are time dependent and ANSYS can both solve distributions as well as create video for time incremental displays of models. 5.5.3. Acoustics / Vibration ANSYS is capable of modeling and analyzing vibrating systems in order to that vibrate in order to analyze Acoustics is the study of the generation, propagation, absorption, and reflection of pressure waves in a fluid medium. Applications for acoustics include the following: Sonar - the acoustic counterpart of radar Design of concert halls, where an even distribution of sound pressure is desired Noise minimization in machine shops Noise cancellation in automobiles Underwater acoustics Design of speakers, speaker housings, acoustic filters, mufflers, and many other similar devices. Geophysical exploration Within ANSYS, an acoustic analysis usually involves modeling a fluid medium and the surrounding structure. Characteristics in question include pressure distribution in the fluid at different frequencies, pressure gradient, and particle velocity, the sound pressure level, as well as, scattering, diffraction, transmission, radiation, attenuation, and dispersion of acoustic waves. A coupled acoustic analysis takes the fluid-structure interaction into account. An uncoupled acoustic 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 assumed to be non-flowing and in viscid (that is, viscosity causes no dissipative effects). Uniform mean density and mean pressure are assumed, with the pressure solution being the deviation from the mean pressure, not the absolute pressure. 5.5.4. Coupled Fields A coupled-field analysis is an analysis that takes into account the interaction (coupling) between two or more disciplines (fields) of engineering. A piezoelectric analysis, for example, handles the interaction between the structural and electric fields: it solves for the voltage distribution due to applied displacements, or vice versa. Other examples of coupled-field analysis are thermal-stress analysis, thermalelectric analysis, and fluid-structure analysis.
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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), magnetic forming (magneto-structural analysis), and microelectro mechanical systems (MEMS). 5.5.5. Modal Analysis 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 can also serve as a starting point for another, more detailed, dynamic analysis, such as a harmonic response or full transient dynamic analysis. Modal analyses, while being one of the most basic dynamic analysis types available in ANSYS, can also be more computationally time consuming than a typical static analysis. A reduced solver, utilizing automatically or manually selected master degrees of freedom is used to drastically reduce the problem size and solution time. 5.5.6 Harmonic Analysis Used extensively by companies who produce rotating machinery, ANSYS Harmonic analysis is used to predict the sustained dynamic behavior of structures to consistent cyclic loading. Examples of rotating machines which produced or are subjected to harmonic loading are: Turbines o Gas Turbines for Aircraft and Power Generation o Steam Turbines o Wind Turbine o Water Turbines o Turbo pumps Internal Combustion engines Electric motors and generators Gas and fluid pumps Disc drives A harmonic analysis can be used to verify whether or not a machine design will successfully overcome resonance, fatigue, and other harmful effects of forced vibrations.

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5.6. Results: 5.6.1. Structural Analysis for bike weight (165 kgs) using Spring Steel as Spring material

FOR 165 kg load Material used: structural steel E: 210000N/mm^2 Poissons Ratio (PRXY): 0.29 Density: 0.000007850kg/mm3

imported model from NX 7.5

Figure 5.6.1

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5.6.2. Meshed Model

FIGURE 5.6.2 5.6.3. Solution step

FIGURE 5.6.3
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5.6.4. Modal analysis

FIGURE 5.6.4 a

FIGURE 5.6.4 b
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FIGURE 5.6.4.c

FIGURE 5.6.4 d

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5.7. Structural Analysis for bike weight (165kgs) using Beryllium Copper as spring material Load=165 kg Material used: beryllium copper E : 280000N/mm2 Poissons Ratio (PRXY) : 0.285 Density :0.000001850kg/mm3

FIGURE 5.7

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5.7.1. Modal Analysis for beryllium copper spring

FIGURE 5.7.1 a

FIGURE 5.7.1 b
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FIGURE 5.7.1 c

FIGURE 5.7.1 d

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5.8. Static structural Analysis of concentric springs Load=165 kg Material used: beryllium copper and spring steel Inner spring: beryllium copper Outer spring: spring steel

FIGURE 5.8

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5.8.1. Modal analysis of concentric springs

FIGURE 5.8.1 a

FIGURE 5.8.1 b
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FIGURE 5.8.1 c

FIGURE 5.8.1 d
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5.9. Graphical Results Steel vs Beryllium copper x(steel)

45 40 35 30 25

y(Berilium copper)

Stress

20 15 10 5 0 -5 0 10000 20000 30000 40000 50000 60000

Nodes
GRAPH 2 Single Spring vs Concentric Springs

x(one spring)
45 40 35 30

y(concentric springs)

Stress

25 20 15 10 5 0 -5 0 10000 20000 30000 40000 50000 60000

Nodes
Graph 3
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6. DYNAMIC ANLAYSIS USING SOLID WORKS

COSMOS Motion is a simulation software package for motion study of any mechanism. Motion study is a term for simulating and analyzing the movement of mechanical assemblies and mechanisms. Motion studies are two types; one is kinematics and the other dynamics. Kinematics is the study of motion without regard to forces that cause it, and dynamics is the study of motions that result from forces. Kinematic simulations show the physical positions of all the parts in an assembly with respect to the time as it goes through a cycle. Dynamic simulation shows joint reactions, inertial forces. The traditional method of performing dynamic and kinematic analysis of any mechanism is preparing the data, solving the algorithms, which involves the solution of simultaneous equations, and analyzing the results. For a complex mechanism like vehicle suspension shown in the following Fig 6. Solving the dynamic equations for motion "by hand" requires intensive calculations, and even with the help of computerized spreadsheet it may take a few hours to get the results and plot the graphs. One can develop a program using software to solve the dynamic equations of motion, but if the geometry of any component changes then the whole program has to be changed again. A design engineer can successfully overcome these problems in motion analysis by using COSMOS Motion simulation software. To analyze the shock absorber using COSMOS Motion, one needs to know: 1. Each joint in the mechanism will have how many degrees of freedom 2. Spring stiffness and damping force in the shock absorber 3. Which parts are moving and which parts are fixed. 4. Input loads such as normal force, lateral force and longitudinal force.

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6.1. Motion Analysis in Solidworks

The road profile is approximated by a sine wave represented by q= Y sint Where, q = Road surface excitation at time t in m. Y= Amplitude of sine wave = 0.02 m. and l = Wavelength of road surface = 6 m.

INPUT VARIABLES: Time=3sec

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Figure 6.1 (a) single degree of damping system

FIGURE 6.1 b
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Analysis of Spring characteristics on an uneven road

Figure 6.1 c

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Responses of model:

GRAPH 4

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GRAPH 5

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7. CONCLUSION In this project we have modelled shock absorber by using nx7.5. To validate the strength of the design we have done the structural analysis on shock absorber. We have done analysis by varying pitch and spring materials i.e., spring steel and beryllium copper. Also the shock absorber design is modified by adding spring in parallel to the existing spring and structural analysis is done on shock absorber. In this paper half bike model is developed for analysis of vibrational effect when it is subjected to harmonic excitation by road profile.

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8. FUTURE SCOPE

A numerical model using ADAMS has to be developed in order to simulate the dynamic behavior of the shock absorber and to describe and evaluate its damping coefficient in compression and rebound cycles. The design of interchangeable shock absorber test rig has to be developed and fabricated for the dynamics measurement system. A full vehicle simulation model has to be developed to get better results.

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9. BIBILOGRAPHY Design of machine elements v.b.bhandari Patel Quarter Model Analysis of Wagan-R cars Rear Suspension using ADAMS Mechanical vibrations theory and applications graham Kelly Comparative Analysis Of Vehicle Suspension System in Matlab-SIMULINK and MSc-ADAMS with the help of Quarter Car Model PSG, 2008.DESIGN DATA, kalaikathir achachgam publishers, COIMBATORE, INDIA Gilles, T. (2005). Automotive Chassis: Brake, Steering & Suspension.: Cencage Learning

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