2019-28-0130 Published 11 Oct 2019 © 2019 SAE International. All Rights Reserved. Modeling and Analysis of Helical and Wave Spring Behavior for Automobile Suspension Soundararajan Ranganathan, Sathishkumar Kuppuraj, Girish Vishnu Rajaram Ganesan, and Jayasuriya Nandhagopal Sri Krishna College of Engg. and Tech. Citation: Ranganathan, S., Kuppuraj, S., Rajaram Ganesan, G.V., and Nandhagopal, J., “Modeling and Analysis of Helical and Wave Spring Behavior for Automobile Suspension,” SAE Technical Paper 2019-28-0130, 2019, doi:10.4271/2019-28-0130. Abstract T he suspension is an indispensable element of automobiles which plays a crucial role in maintaining stability and the ride comfort. Helical springs are used in automobile suspension for many decades. Te stifness of the spring and presence of shock absorber plays a major role while negotiating a huge amount of load. Terefore, the cost of the suspension increases proportionally in commercial vehicles. In this present work, a helical and wave spring is designed and static cum dynamic analysis is done by using ANSYS 18.1 for comparing their performance and to eliminate the downside of the suspen- sion. Te geometry of the helical spring is designed using the helix curve and wave spring is designed using Sinusoidal equation. Modeling of both the springs is done using Solid works 2018. Chrome silicon and music wire are chosen as a spring material. Te responses like stress and defection of helical spring and wave spring for both the materials under static loads of 3000 N, 3500 N, 4000 N is obtained. Further, the dynamic analysis is conducted on both the springs under tran- sient load conditions to obtain their responses. Output results such as total deformation and von-misses are taken in each loading condition, and the responses are compared. Te results show that wave spring of chrome silicon has better properties in both static and dynamic load conditions. From the analysis, it is concluded that the use of helical spring with shock absorber system can be replaced by the newly developed chrome silicon wave spring suspension system. Due to this system incorpora- tion in the vehicles, the free length is reduced. Introduction T he automobile suspension is the primary absorber of shocks and vibrations from the road without causing discomfort to the passengers. Te suspension system is an indispensable element in protecting the chassis of the vehicle from being damaged due to irregularities on the road [1]. Te suspension provides reactive force to ensure the contact of the tires and road, in all surface conditions. Te suspension uses springs as an elastic component [2]. Suspensions cut down the amplitude of disturbances and enhance ride quality and ride comfort [3]. Spring is elucidated as an elastic body which deforms on the application of load and regains its primeval shape on de-loading. Te diferent types of springs available in the market are helical spring, conical springs, torsion spring, and leaf spring. Out of these springs Helical springs are predom- inantly used in automobile suspensions [4]. Te wire wound in a helix pattern to take up compressive or tensile loads forms helical springs. Te wires used to make helical springs have a circular, square, or rectangular cross-section. [5].Te wave spring considered in the analysis is a crest to crest wave spring with multiple turns and no shim ends [6]. A large number of elastic materials are used to fabricate springs and spring steel is more widely used. Pre-hardened steel, annealed and hardened steel is also used to wound helical springs. [7] In this present work wave spring and helical spring made of two most widely used material such as ASTM A401 and ASTM A228 respectively. Further automobile suspension is designed using solid works 2016 sofware. Te static analysis and dynamic analysis is performed on the springs of diferent material to calculate the equivalent stress and total deformation. Te best spring design and the type of material for that spring are found from the analysis results. Tis paper focuses on the reduction of material used for manu- facturing spring and to improve the stability of the vehicle by decreasing the ground clearance of the vehicle by using wave spring. Keywords Helical spring, Wave spring, Von-mises stress, Total Deformations ASTM A228, ASTM A401, Structural analysis and Dynamic analysis. Downloaded from SAE International by Sathish Kumar K, Wednesday, October 16, 2019