A Project Report On

DESIGN AND ANALSYS OF TWO WHEELER SUSPENSION SYSTEM

The thesis submitted in partial fulfillment of

The requirements for the award of the degree of

BACHELOR OF TECHNOLOGY
In
MECHANICAL ENGINEERING

Submitted By
G. Naveen 13371A0323

K. Rahul 13371A0335

T. Rajashekar 13371A0383

K. Chandrakanth 14375A0303

Under the Esteemed guidance of

Mr. K. RAKESH VARMA (M. TECH)

Asst. Professor

DEPARTMENT OF MECHANICAL ENGINEERING

Dr. Paul Raj Engineering College, Bhadrachalam

(Affiliated to JNTU, Hyderabad)

Approved by AICTE, New Delhi

Bhadrachalam 507111
 Dr. PAUL RAJ ENGINEERING COLLEGE

(Affiliated to JNTU, Hyderabad)

Approved by AICTE, New Delhi

Bhadrachalam 507111

DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE

This is to certify that the thesis entitled

"Design Analyses of two wheeler suspension system"

Is a bonafied work done by

G. Naveen 13371A0323

K. Rahul 13371A0335

T. Rajashekar 13371A0383

K. Chandrakanth 14275A0303

During 2016-2017 in partial fulfillment of the

Requirements for the award of the Degree of

Bachelor of Technology in Mechanical Engineering

K. Rakesh varma M. Tech R. Sathish

Internal Guide Head of the Department

Assistant Professor Assistant Professor

External Examiner
 Acknowledgment

We owe a great many thanks to a great many people who helped and supported us during
the writing of this paper.

Our deepest thanks to K. Rakesh Varma M. tech the project guide of the Mechanical
engineering for guiding and correcting various documents of ours with attention and care.
He has taken pain to go through the paper and make necessary correction as and when
needed.

We acknowledge with thanks for all the valuable help rendered by Mr. R. Sathish, M. tech
head of the department of mechanical engineering.

We express my thanks to the principle of Dr. Paul Raj Engineering College, Bhadrachalam
for extending his support.

We would also thank my institution and my faculty members without whom this paper
would have been a distant reality. Also extend my heartfelt thanks to my family and well-
wishers.

With Sincere Regards,

G. Naveen 13371A0324

K. Rahul 13371A0335

T. Rajashekar 13371A0383

K. Chandrakanth 14375A0303
 DESIGN AND ANALYSIS OF TWO WHEELER

SUSPENSION SYSTEM

ABSTRACT

During the tractor movement, with being attached to the hitch-system working equipment over

rough road surfaces oscillation of the machine take place. These oscillations are a reason of

pressure pulsations in the hydraulic hitch-system. The pressure pulse reduction in the tractor

hitch-system is important for increasing of the system components lifetime. Pressure oscillation

damping in the tractor hydraulic hitch-system can reduce overall system oscillations and improve

the driving control.

The design of spring in suspension system is very important. In this project a shock

absorber is designed and a 3D model is created using CATIA. The model is also changed by

changing the thickness of the spring.

Structural analysis and modal analysis are done on the suspension system by varying

material for spring, Spring Steel and Beryllium Copper. The analysis is done by considering

loads, bike weight, single person and 2 persons. Structural analysis is done to validate the

strength and modal analysis is done to determine the displacements for different frequencies for

number of modes. Comparison is done for two materials to verify best material for spring in

suspension system. An analysis is done in ANSYS.

 1. INTRODUCTION TO CAD

Computer-aided design (CAD) is the use of computer systems (or workstations) to aid in the

creation, modification, analysis, or optimization of a design. CAD software is used to increase

the productivity of the designer, improve the quality of design, improve communications through

documentation, and to create a database for manufacturing. CAD output is often in the form of

electronic files for print, machining, or other manufacturing operations. The

term CADD (for Computer Aided Design and Drafting) is also used.

Its use in designing electronic systems is known as electronic design automation, or EDA.

In mechanical design it is known as mechanical design automation (MDA) or computer-aided

drafting (CAD), which includes the process of creating a technical drawing with the use

of computer software.

CAD software for mechanical design uses either vector-based graphics to depict the objects of

traditional drafting, or may also produce raster graphics showing the overall appearance of

designed objects. However, it involves more than just shapes. As in the

manual drafting of technical and engineering drawings, the output of CAD must convey

information, such as materials, processes, dimensions, and tolerances, according to application-

specific conventions.

CAD may be used to design curves and figures in two-dimensional (2D) space; or curves,

surfaces, and solids in three-dimensional (3D) space.

CAD is an important industrial art extensively used in many applications,

including automotive, shipbuilding, and aerospace industries, industrial and architectural

design, prosthetics, and many more. CAD is also widely used to produce computer

animation for special effects in movies, advertising and technical manuals, often called

DCC digital content creation. The modern ubiquity and power of computers means that even

perfume bottles and shampoo dispensers are designed using techniques unheard of by engineers

of the 1960s. Because of its enormous economic importance, CAD has been a major driving

force for research in computational geometry, computer graphics (both hardware and software),

and discrete differential geometry.

2. INTRODUCTION TO CATIA

CATIA (an acronym of computer aided three-dimensional interactive application,

pronounced is a multi-platform software suite for computer-aided design (CAD), computer-aided
manufacturing (CAM), computer-aided engineering (CAE), PLM and 3D, developed by the
French company Dassault Systems.

As Dassaults pioneer brand, CATIA goes far beyond traditional 3D CAD software tools,
offering a lifelike design experience that allows stakeholders and designers to visualize and
experiment with products throughout its development. CATIA is the worlds leading solution for
product design and innovation. Companies of all sizes use CATIA to ensure their products real
success. Increasing the power of innovation for designers, engineers, product and systems
architects, and systems engineers is the ultimate mission of Dassaults leading brand. Combining
the digital mock-up experience with a functional pipeline, Dassault has created a Digital Product
Experience that makes it possible to reuse the same component in its geometric view, as well as
in its functional view.

CATIA delivers the unique ability not only to model any product, but to do so in the context of
its real-life behavior: design in the age of experience. Systems architects, engineers, designers
and all contributors can define, imagine and shape the connected world.

CATIA, powered by Dassault Systems 3DEXPERIENCE platform, delivers:

A Social design environment built on a single source of truth and accessed through powerful 3D
dashboards that drive business intelligence, real-time concurrent design and collaboration across
all stakeholders including mobile workers.

An Instinctive 3D EXPERIENCE, for both experienced and occasional users with world-class
3D modeling and simulation capabilities that optimize the effectiveness of every user.

An Inclusive product development platform that is easily integrated with existing processes &
tools. This enables multiple disciplines to leverage powerful and integrated specialist
applications across all phases of the product development process.

CATIAs Design, Engineering and Systems Engineering applications are the heart of Industry
Solution Experiences from Dassault Systems to address specific industry needs. This
revolutionizes the way organizations conceive, develop and realize new products, delivering
competitive edge through innovative customer experiences.

2.1 Scope of application

Commonly referred to as a 3D Product Lifecycle Management software suite, CATIA supports

multiple stages of product development (CAX), including conceptualization, design (CAD),
engineering (CAE) and manufacturing (CAM). CATIA facilitates collaborative engineering
across disciplines around its 3DEXPERIENCE platform, including surfacing & shape design,
electrical, fluid and electronic systems design, mechanical engineering and systems engineering.

CATIA facilitates the design of electronic, electrical, and distributed systems such as fluid
and HVAC systems, all the way to the production of documentation for manufacturing.

2.2 Mechanical engineering

CATIA enables the creation of 3D parts, from 3D sketches, sheet metal, composites, and molded,
forged or tooling parts up to the definition of mechanical assemblies. The software provides
advanced technologies for mechanical surfacing & BIW. It provides tools to complete product
definition, including functional tolerances as well as kinematics definition. CATIA provides a
wide range of applications for tooling design, for both generic tooling and mold & die.

2.3 Design
CATIA offers a solution to shape design, styling, surfacing workflow and visualization to create,
modify, and validate complex innovative shapes from industrial design to Class-A surfacing with
the ICEM surfacing technologies. CATIA supports multiple stages of product design whether
started from scratch or from 2D sketches.

2.4 Systems engineering

The CATIA Systems Engineering solution delivers a unique open and extensible systems
engineering development platform that fully integrates the cross-discipline modeling, simulation,
verification and business process support needed for developing complex cyber-physical
products. It enables organizations to evaluate requests for changes or develop new products or
system variants utilizing a unified performance based systems engineering approach. The
solution addresses the Model Based Systems Engineering (MBSE) needs of users developing
todays smart products and systems and comprises the following elements: Requirements
Engineering, Systems Architecture Modeling, Systems Behavior Modeling & Simulation,
Configuration Management & Lifecycle Traceability, Automotive Embedded Systems
Development (AUTOSAR Builder) and Industrial Automation Systems Development (Control
Build).

CATIA uses the open Modelica language in both CATIA Dynamic Behavior Modeling
and Dymola, to quickly and easily model and simulate the behavior of complex systems that
span multiple engineering disciplines. CATIA & Dymola are further extended by through the
availability of a number of industry and domain specific Modelica libraries that enable user to
model and simulate a wide range of complex systems ranging from automotive vehicle
dynamics through to aircraft flight dynamics
3. CATIA MODULES
1. Sketcher
2. Part modeling
3. Assembly
4. Drafting
5. Wire frame and surfaces design.

3.1 MODEL OF SUSPENSION SYSTEM USING CATIA SOFTWARE

Top Part (3.1)

Helical spring (3.3)
Casing (3.2)

)
Inner body (3.3)

Lower (3.4)
 Total Assembly (3.7)

2D Drawing of Helical Spring (3.8)

 4. INTRODUCTION TO FEA

Finite element analysis is a method of solving, usually approximately, certain problems in

engineering and science. It is used mainly for problems for which no exact solution, expressible

in some mathematical form, is available. As such, it is a numerical rather than an analytical

method. Methods of this type are needed because analytical methods cannot cope with the real,

complicated problems that are met with in engineering. For example, engineering strength of

materials or the mathematical theory of elasticity can be used to calculate analytically the

stresses and strains in a bent beam, but neither will be very successful in finding out what is

happening in part of a car suspension system during cornering.

One of the first applications of FEA was, indeed, to find the stresses and strains in engineering

components under load. FEA, when applied to any realistic model of an engineering component,

requires an enormous amount of computation and the development of the method has depended

on the availability of suitable digital computers for it to run on. The method is now applied to

problems involving a wide range of phenomena, including vibrations, heat conduction, fluid

mechanics and electrostatics, and a wide range of material properties, such as linear-elastic

(Hookean) behavior and behavior involving deviation from Hooke's law (for example, plasticity

or rubber-elasticity).

Many comprehensive general-purpose computer packages are now available that can deal with a

wide range of phenomena, together with more specialized packages for particular applications,

for example, for the study of dynamic phenomena or large-scale plastic flow. Depending on the

type and complexity of the analysis, such packages may run on a microcomputer or, at the other

extreme, on a supercomputer. FEA is essentially a piece-wise process. It can be applied to one-

dimensional problems, but more usually there is an area or volume within which the solution is
required. This is split up into a number of smaller areas or volumes, which are called finite

elements. Figure 1 shows a two-dimensional model of a spanner that has been so divided: the

process is called description, and the assembly of elements is called a mesh.

5. INTRODUCTION TO ANSYS

5.1 Structural Analysis

ANSYS Autodyne is computer simulation tool for simulating the response of materials to short

duration severe loadings from impact, high pressure or explosions.

5.2 ANSYS Mechanical

ANSYS Mechanical is a finite element analysis tool for structural analysis, including linear,

nonlinear and dynamic studies. This computer simulation product provides finite elements to

model behavior, and supports material models and equation solvers for a wide range of

mechanical design problems. ANSYS Mechanical also includes thermal analysis and coupled-

physics capabilities involving acoustics, piezoelectric, thermalstructural and thermo-electric

analysis.

5.3 Fluid Dynamics

ANSYS Fluent, CFD, CFX, FENSAP-ICE and related software are Computational Fluid

Dynamics software tools used by engineers for design and analysis. These tools can simulate

fluid flows in a virtual environment for example, the fluid dynamics of ship hulls; gas turbine

engines (including the compressors, combustion chamber, turbines and afterburners); aircraft
aerodynamics; pumps, fans, HVAC systems, mixing vessels, hydro cyclones, vacuum cleaners,

etc.

6. MATERIAL PROPERTIES
6.1 Structural steel

Density: 7850kg/m3

Ultimate Tensile Strength: 515-827Mpa

Yield Tensile Strength: 207-552Mpa

Youngs Modulus: 190-210Gpa

Poissons Ratio: 0.30

% of elongation: 12-40

6.2 Beryllium copper

Density: 8260 Kg/m3

Ultimate Tensile Strength: 483-810Mpa

Yield Tensile Strength: 221-1172Mpa

Youngs Modulus: 115Gpa

Poissons Ratio: 0.30

Shear Modulus: 50Gpa

 7. STRUCTURAL ANALYSIS OF TWO WHEELER SUSPENSION

SYSTEM
7.1 MATERIAL - STRUCTURAL STEEL
Open ANSYS>Open work bench 14.5>select static structural >double click on it.

Static structural (7.1)

Select engineering data> window will be open in that enter required material properties>

update project and return to the project.

Select geometry > right click on it >select import geometry> select file>ok

IMPORTED MODEL (7.2)

Select model>right click on it> select edit> window will be open in that select mesh>right

click on it>select generate mesh

MESHED MODEL (7.3)

Select static structural >right click on it >insert> pressure> select area> enter magnitude>

apply.

PRESSURE (7.4)
Select static structural >right click on it >insert> fixed support> select area> apply.

FIXED SUPPORT (7.5)

 Right click on solution> insert > Deformation >Total>Right click on solution> insert>

Strain> Equivalent (Von-mises)> Right click on solution> insert> Stress> Equivalent (Von-

mises). Right click on solution> insert > Solve.

7.1.1 LOAD (113KG)

STRESS (7.1.1.1)
 STRAIN (7.1.1.2)

TOTAL DEFORMATION (7.1.1.3)

7.1.2 LOAD (188KG)

 STRESS (7.1.2.1)

STRAIN (7.1.2.2)
TOTAL DEFORMATION (7.1.2.3)

7.1.3 LOAD (263KG)

STRESS (7.1.3.1)
 STRAIN (7.1.3.2)

TOTAL DEFORMATION (7.1.3.3)

7.2 MATERIAL - BERYLLIUM COPPER
7.2.1 LOAD (113KG)

STRESS (7.2.1.1)

STRAIN (7.2.1.2)
TOTAL DEFORMATION (7.2.1.3)

7.2.2 LOAD (188KG)

STRESS (7.2.2.1)
 STRAIN (7.2.2.2)

TOTAL DEFORMATION (7.2.2.3)

7.2.3 LOAD (263KG)

STRESS (7.2.3.1)

STRAIN (7.2.3.2)
TOTAL DEFORMATION (7.2.3.3)
 8. MODAL ANALYSIS OF TWO WHEELER SUSPENSION

SYSTEM

ANSYS> Work bench 14.5>Double click on Modal.

Model (8.1)

Right click on Engineering data>edit>apply material properties>return project>Update project.

Right click on Geometry>Imported Geometry>browse>click on IGS file>Open.

IMPORTED GEOMETRY (8.2)

Right click on Model>Edit>Right click on mesh>sizing>fine>Right click on mesh>generate

mesh.

MESHED MODEL (8.3)

Right click on Modal>Insert>Fixed supports>Select faces>apply.

FIXED SUPPORT (8.4)

Right click on Solution>Insert>Deformation>Total>Mode1.

Right click on Solution>Insert>Deformation>Total>Mode2..etc.

Right click on Solution >Solve.

8.1 MATERIAL - STRUCTURAL STEEL

Fig (8.1.1)

Fig (8.1.2)
Fig (8.1.3)

Fig (8.1.4)
 Fig (8.1.5)

Fig (8.1.6)

RESULTS FOR 6 MODE SHAPES

8.2 MATERIAL - BERYLLIUM COPPER

Fig (8.2.1)

Fig (8.2.2)
Fig (8.2.3)

Fig (8.2.4)
 Fig (8.2.5)

Fig (8.2.6)

RESULTS FOR 6 MODE SHAPES

 9. DESIGN CACULATIONS FOR TWO WHEELAR SUSPENSION

SYSTEM

Mean diameter of a coil D=62mm

Diameter of wire d = 8mm

Total no of coils n1= 18

Height h = 228 mm

Outer diameter of spring coil D0 = D +d =70mm

No of active turns n= 14

Weight of bike acting on suspension = 113kgs

Let weight of 1 person = 75Kgs.

Weight of 2 persons = 752=150Kgs.

Weight of bike + persons = 263Kgs

Rear suspension = 65% of 263 = 170Kgs

Considering dynamic loads it will be double W =340Kgs = 3335N.

For single shock absorber weight = w/2= 1667N = W

We Know that,

Compression of spring () = 8FC3nGd4 = 138.212mm

C = spring index = 7.75 = 8

Solid length, Ls=n1d=188=144 mm

Free length of spring, Lf = solid length+ maximum compression +Clearance between

adjustable coils X 0.15 = 144 + 138.212 + 0.15 138.212 = 302.943 mm

Spring rate, K. =F/ = 26 N/mm

Pitch of coil, P. = 19 mm
 10. RESULTS TABLE FOR STRUCTURAL ANALYSIS
10.1 LOAD CALCULATION

LOAD CONVERSION IN PRESSURE[MPa]=

LOAD ON LOAD ON NEWTONS[1kg=9.81N] LOAD/AREA

TWO SINGLE AREA=3848.45mm2

SHOCKS SHOCK

113kg 56.5kg 554.265N 0.144MPa

188kg 94kg 922.14N 0.239MPa

263kg 131.5kg 1290.015N 0.335MPa

10.2 STRUCTURAL ANYLYSIS RESULTS

VON-MISES TOTAL
LOAD(KG VON-MISES
MATERIAL STRESS DEFORMATION
) STRAIN
[MPa] [ mm]
Structural
113
steel 227.68 0.0015 13.702

188
377.89 0.0025 22.741

263
529.68 0.0035 31.875

Beryllium
113
copper 233.23 0.0026 23.794
188
 387.1 0.0044 39.492

263
542.59 0.0062 55.355
11. RESULTS TABLE FOR MODAL ANALYSIS
11.1 Structural steel

Deformation Frequency

(mm) (Hz)
Mode 1 36.15 5.1808
Mode 2 36.171 5.1969
Mode 3 27.993 17.776
Mode 4 41.443 30.481
Mode 5 45.04 31.103

11.2 Beryllium copper

Deformation Frequency

(mm) (Hz)
Mode 1 35.241 3.8298
Mode 2 35.261 3.8417
Mode 3 27.29 13.14
Mode 4 40.401 22.532
Mode 5 44.397 22.847

12. CONCLUSION
In this project, a two wheeler suspension system is designed and modeled in 3D modeling

software CATIA. Structural and Modal analysis is done on suspension system at different loads

113Kg, 188Kg and 263Kg for different materials Structural steel and Beryllium Copper.

By observing the structural analysis results, the stress value is less for Beryllium Copper than

Structural steel but the deformation is more.

By observing the modal analysis results, the deformation and frequency are less for Beryllium

Copper than Structural Steel. Due to less frequency, the vibrations of suspension system when

Beryllium Copper is used are less.

So it can be concluded that using Beryllium Copper is better.

BIBILOGRAPHY

1. MACHINE DESIGN BY R.S. KHURMI

2. PSG, 2008.DESIGN DATA, KALAIKATHIR ACHCHAGAM PUBLISHERS,

COIMBATORE, INDIA