Experimentation for Design Improvements for Coil Spring in the Independent Suspension 2020-01-0503
The objective of this project is to analyze potential design changes that can improve the performance of helical spring in an independent suspension. The performance of the helical spring was based upon the result measure of maximum value of stress acting on it and the amount displacement caused when the spring undergoes loading. The design changes in the spring were limited to coil cross section, spring diameter (constant & variable), pitch and length of the spring. The project was divided into Stage I & Stage II. For Stage I, using all the possible combinations of these design parameters, linear stress analysis was performed on different spring designs and their Stress and displacement results were evaluated. Based on the results, the spring designs were classified as over designed or under designed springs. Then in Stage II, it was checked if the under designed springs can be optimized and classified according to a relevant application of the vehicles (racing cars or luxurious cars).
The driving factor for this project was the amount of research that has taken place to improve the performance of suspension spring. It was seen that most of the research done in this field was directly or indirectly connected to the manufacturing of the spring. It is correct direction indeed, because the helical springs used in suspensions are made of complex alloys and better manufacturing would definitely improve its performance. But for this project, the focus remained on trying new direction for improving performance of spring. After much thought it was decided that bringing design changes to the spring should be experimented and it should be checked if certain design parameters which theoretically could improve spring performance, can they be put together and give positive results.