Shock Absorber Test Rig

1. INTRODUCTION

Suspension system is an assembly used to support weight, absorb and dampen road
shock, and help maintain tire contact as well as proper wheel to chassis relationship.
A vehicle in motion is more than wheels turning. As the wheel revolves, the
suspension system is in a dynamic state of balance, continuously compensating and
adjusting for changing driving conditions. Suspension of vehicle need to analyse
before be manufacturing. This is because to make sure components in shock absorber
system remain in good conditions. On the other hand, shock absorber system need to
analyse how shock to see how they going to perform in worst-case scenario.[1]

A safe vehicle must be able to stop and man over a wide range of road conditions.
Good contact between the tires and the road will able to stop and man oeuvre quickly.
Suspension is the term given to the system of springs, shock absorbers and linkages
that connects a vehicle to its wheels. Shock absorber is an important part of
automotive suspension system which has an effect on ride characteristics. Shock
absorbers are also critical for tire to road contact which to reduce the tendency of a
tire to lift off the road. This affects braking, steering, cornering and overall stability.
The removal of the shock absorber from suspension can cause the vehicle bounce up
and down.[2]

It is possible for the vehicle to be driven, but if the suspension drops from the driving
over a severe bump, the rear spring can fall out. Basically, the shock absorbers must
be replaced after driving exceeds certain distance. But this actually not should have
been followed if there are no defective. To ensure there are no defective, the
consideration to check the condition of the shock absorber is the best way. There are
several methods to test the condition of the shock absorber. One of the tests is
endurance test use frequency response method which applied to the suspension and
tire. But this test is very complicated and costly because the machine is very
expensive.[3]
The other method to check the shock absorber without removing from the vehicle is
by using the bounce test. In the workshop, some mechanics will perform bounce test
which is push down each corner of the car several times to check the condition of
shock absorber. However, the result of this test is not very accurate to indicate the
condition of shock absorbers. The objectives of this paper are to determine the
dynamic characteristics of automotive shock absorber systems. Running vehicles are
exposed to almost constant vibration excitation; shock (i.e. Vibration) absorbers are
consequently required for reasons of driving safety and riding comfort. These aims
partly conflict, because a taut suspension prevents wheel hopping and thus a loss of
road contact, whereas a soft suspension is supposed to reduce body vibration and thus
the annoying effects of acceleration on the occupants. For many years, the semi-
elliptic leaf springs used on carts and carriages were the most common method of
providing suspension springing. This was a neat and simple arrangement, but it

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 Shock Absorber Test Rig

unfortunately produced a number of problems such as a tendency of the axle to wind

up around the springs on braking or acceleration. Pneumatic variable height
suspension was developed for family cars by Citroën, and has also been used on
commercial vehicles. Now-a-days the dampers used in almost all the passenger
vehicle are hydraulic. This is because the damping effect due to hydraulic oil is much
more effective than the conventional methods of damping.[3]

1.1 Problem Definition

1.1.1 Problem Statement
To design and development of “MULTIPURPOSE MACHINE” is a structure which is
designed for the purpose of multi-operations i.e. drilling, cutting & shaping. The present
machines have limited work stations on single machine, and the number of operations
performed on them are limited. The cost of the existing machines is high, also the
efficiency is low. The time required for work piece handling is more. The floor
space utilization of these existing machines is poor as they require large space. The
energy consumption is also high.
1.1.2 Problem Identification
This machine perform multipurpose operation at same time with required speed & this
machine is automatic which is controlled or operated by motor which is run with the help
of current. This machine is based on the mechanism of Scotch Yoke Mechanism. This
model of the multi operational machine is may be used in industries and domestic
OPERATION which can perform mechanical operation like drilling, cutting & shaping of
a thin metallic as well as wooden model or body
1.2 Methodology
In this project, we will give the power supply from the electric motor to the shaft
by pulley and belt drive on which a bevel gear is mounted on it, and a second
bevel gear at a right angle to it has been mounted on a drill shaft to which a drill bit is
being attached and at the other end of the shaft a buffing wheel is mounted. The second
shaft is connected to power supply through pulley and belt drive, one end of the shaft
is being joint to a circular disc, through this circular disc scotch yoke mechanism is

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 Shock Absorber Test Rig

being performed (rotary motion is being converted to reciprocating motion) and at

the other end of the shaft motion is also transmitted to grinding wheel.
1.3 Future scope
-There could be chance of failure when all operations are simultaneously working so
respective care should be taken.
-More flexible model with more operations and with more capacity can be produced.

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2.LITERATURE REVIEW
Before starting our work we have undergone through many research papers which
indicates that for a production based industries machine installation is a tricky task as
many factor being associated with it such as power consumption (electricity bill per
machine), maintenance cost, no of units produced per machine i.e. capacity of machine,
time consumption and many more.
Some research papers which have led us to approach to the idea of a machine which may
give solution to all these factors are as follows:
1 ]Y.Ping.”Experimental and mathematical evaluation of dynamic behaviour of an
oil-air coupling shock absorber”, Elseveir, vol.17, Issue no.6,pp.1367-79,20032.
3 A.K.Samantray,”Modelling and analysis of preloaded liquid spring/damper shock
absorber”, Simulation modelling practice and theory, vol.17,pp. 309-325,2009
[4]Peng et al., ”The force transmissibility of MDOF structures with a non linear
viscous damping device”, International journal of non linear mechanics, Elsevier,
vol.46, pp.1305-14,2011
[5]W.J.Hsueh.”Vibration transmissibility of a unidirectional multidegree of freedom
system and multiple dynamic behaviour”, Journal of sound and vibration, vol.229,
Issue no.4, pp793-05, 2000
[6]C.Lee, B.Y.Moon,”Simulation and experimental validation of vehicle dynamic
characteristics for displacement sensitive shock absorber using fluid flow”,
Sciencedirect, vol. 20,pp. 373-88,2006

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 Shock Absorber Test Rig

3. Design of Test Rig

3.1 Conceptual Design
The conceptual design involves the selection of the standard parts required for the test rig
as follows

3.1.1 DC motor
Specification: power = 0.5 HP =0.37 KW (1HP=746 Watt) Speed = 1500 rpm

3.1.2 Strip Chart recorder

It is used to record the motion of the shock absorber under different loading and speed
conditions. Readings can be taken on the strip chart recorder with the help of the pen
arrangement.

3.1.3 Circular disc

The disc used is to convert the rotary motion of the motor shaft into the linear motion of
the shock absorber. To achieve this purpose the appropriate eccentricity is provided to the
disc. The disc presentlyused is having an eccentricity of 2.5 cm. figure 1 shows the disc
and its different views.
3.2Mathematical Design

3.2.1Maximum force acting on the roller: Motor Power = P = 0.5 HP= 0.37 KW

Motor is run at 1500 rpm so that it can lift the shock absorber and also produces
maximum torque.

P=(2πNT) / (60) (2)

Where, P = Motor Power , N=
r.p.m., T = Torque

Therefore,
(0.37×103)=(2π×1500×T)(60)
T= 70.66 Nm

Torque is given as, T= F×R (3)

Where, F= Force acting on roller
R= Distance between the centre of eccentricity to the motor output shaft.
=(0.04+0.012) m
Therefore,
70.66= F × (0.04+0.012) F=1358.84 Newton F=1360 Newton

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 Shock Absorber Test Rig

As total force acting downwards (Weight of the bushes +Max dead weight can be added)
= 5+4 = 9 kg= 90 Newton is less than the force acting upwards (1360 Newton). So that
shock absorber is easily lifted upwards by the disc.

3.2.2Selection of Bearing
The deep groove ball bearing is selected to convert the rotary motion of the disc into the
linear motion of the shock absorber. The protruded rod of the disc is fitted into the inner
race of the bearing and outer race rotates and converts the rotary motion of the disc into
linear motion of the shock absorber simultaneously.
Now from equation 3,
Radial load (Fr) = 1360 N, Axial load (fa) = 0 N
Assuming static load carrying capacity Co = 3550
Fa / Fr = 0 & Fa / Co = 0 X= Radial factor Y = Axial factor
So taking X = 1 & Y= 0 P = X Fr + Y Fa
Effective load = P =1360 N
Assuming bearing life
Lh = 8000 Hrs Life L = 60 n Lh / 106
L = 60×150×8000 / 106 = 72 L = ( C / P)3
For ball bearing Therefore,
C= (1360 × 72 1/3) ×1.2
C= 6789.39 N < 7800 N So design is safe.
So we selected the bearing no. SKF-6202.

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4.DESIGN OF MODEL

2.3 Cam and follower:

The specifications of cam and follower are as follows:
1.Eccentric cam and roller follower.
i.Maximum displacement =50 mm
ii.Angle of rise =180 degree
iii.Angle of return =180 degree
iv.Diameter of base Circle =50 mm
v.Diameter of Roller Follower = 30 mm
2.Rise and return considering SHM.
vi.Thickness of Cam disc =16 mm
vii.Eccentric radius of cam =25 mm

2.4 Pedastal Bearing and Jaw coupling:

Based upon the maximum load (Radial load) acting on the shaft i.e. 1000N and
assumed, rating life of bearing to be 12000 hours and inner race factor to be 1.2. Based
upon load and assumptions we selected a bearing (P204) having I.D of 20 mm.

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As the maximum torque to be transmitted by the motor and gearbox is 50Nm Based
upon which we selected a jaw coupling from the catalogue having dimensions as follows:
Input shaft 14.5
i.diameter = mm
Output shaft
ii.diameter =20 mm
Outer diameter of
iii.hub = 32 mm

2.5 Drive System:

The Drive system is an integral part of the suspension test rig setup. The major
function of the drive system is to produce the exciting force and to transmit this force to
the Cam mechanism.

The tasks required to be performed by the drive system are:

i.To provide the driving force with the help of prime mover.
ii.To couple the output shaft of motor and the input shaft of the gearbox.
iii.To convert the speed of the motor to the required speed with the help of the gearbox.
iv.To connect the output shaft of the gearbox to the shaft of the cam disc.

2.5.1Drive System Requirements:-

Taking into consideration different factors, the required speed from the gearbox
has been chosen as 300 RPM and the Motor speed has been chosen as 3000 RPM.
Torque requirement:-

Torque: T= F x r
= (mg) x r
Where,
T - Torque required.
F - Force at the damper.
r - Moment arm or torque arm.
Thus, for a 100 kg force acting at a moment arm of 0mm the torque required is:- T = F x r

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=(mg) x r Power requirement:

P = 2ΠNT
60 =1.08678 KW
Where,
P - Minimum motor power. N - Motor speed in RPM. T - Torque required.
For maximum motor speed of 300 rpm we get,
Based on the above requirements the different components selected in the drive system
are as follows:-

2.5.2 DC Motor:
Taking into consideration the possibility of testing dampers with a greater
damping force at higher velocities the motor with the following specifications has been
selected.
Speed:-Maximum speed available 3000 rpm which can be controlled using speed
regulator (dimmer stat)
Power:-1.5 HP (1.12 KW). Shaft size: 15 mm.

Advantages:
i.DC motor provides us with more Flexibility as we can operate the test rigs at a required
speed.
ii.Due to higher power capacity (1.5 HP) motor, Dampers with high Damping coefficient
can also be tested with ease.

2.6 Reduction System:

The main function of the reduction system is to provide an efficient speed
reduction as well as to achieve required torque from the specific motor speed to the
required actuation speed. In our case we require a reduction system to reduce the motor
speed of 3000 RPM to the maximum actuation speed of 300 RPM. To accomplish this
task, there are various types of reducers available, some of these are:-
i.Chain sprocket
ii.Belt and pulley
iii.Gearbox

2.6.1Features of gear reducer:Advantages:

i.Compact drive requirements demand the shortest possible distance between shaft
centers.
ii.High speed ratios are required.
iii.High rotating speeds (RPM) are required.
iv.High horsepower AND high speed loading is required.
v.High Efficiency.

2.7Riverted gear train:

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When the axes of the first gear and the last gear (i.e. last driven or follower)
are co-axial then, the gear train is known as riverted gear train.

Spur gear terminology used in calculation:

T1 = Number of teeth on gear no 1
R1 = Pitch circle radius of gear no1
N1 = Speed of gear no 1 in rpm
Similarly,
Number of teeth on respective
T2, T3, T4 = gears.
Pitch circle radii of respective
R2, R3, R4 = gear.
= Speed of respective gear in
N2, N3, N4 rpm.
Pc = Circular pitch
=
M Module
Φ= Pressure angle
= Distance between two
X shafts.

Input Data:
i.Shaft diameter = 20 mm
ii.Pressure angle of spur gear = Φ20
= 1000
iii.Input speed = N1 rpm
= 200
iv.Output speed =N4 rpm
v.Module of gears = 1.5 mm
vi.Distance between two shaft=R = 120 mm

Solution:
We know that circular
pitch,
Pc = 2πR = πM or R = MT
T 2
R1 = MT1 , R2 = MT2 , R3 = MT3 , R4 = MT4
2 2 2 2
MT1 + MT2 = MT3 + MT4
2 2 2 2
Therefore, T1 + T2 = T3 + T4
Since the speed ratio between the gears a & b and between the gears c & d are to be same.,
therefore ,

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Na Nc = √Na =1000 = 2.24

Nb Nd √ Nd 200
We know that,
Nb = Ta
Na Tb
Na = 1 revolution
Since, therefore, Nb = Ta
Tb
Also the speed ratio of any pair of gear in mesh is the inverse of their Number of teeth
therefore,
Tb = Td = 2.24
Ta Tc
We know that the distance between the
shafts:
X = Va + Vb = Rc + Rd = 120 mm
OR
Mc Tc + Md Td
Ma Ta +Mb Tb = =120
2 2 2 2
1.5 ( Ta + Tb ) = 1.5 ( Tc + Td ) = 240
Ta + Tb = 240 = 160
1.5
Tc + Td = 240 = 160
1.5
And From equation above,

Tb = 2.24
Since,
Ta + 2.24 Ta = 160

3.24Ta = 160
Ta = 49.38 say 50
Tb = 160-50 = 110
And From
equation Td = 2.2 Tc
Tc + 2.24
Tc = 160
Tc = 160
3.24
49.36 Say
Tc = 50

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 Shock Absorber Test Rig

Td = 160 -
50 = 110
By Checking,
Na = Tb * Td
Nd Ta * Tc
Ra = m Ta
2
= 1.5 x 50
2
Ra = 37.5 mm
Da = 75 mm
Therefore,
Rb = 82.5 mm
Rc = 37.5 mm
Rd = 82.5 mm

5. OPERATIONS PERFORMED

6. EXPECTED OUTCOMES
1) We reduce the machining time for drilling considerably
2) We reduce the machining time for sawing considerably
3) We reduce the machining time for grinding considerably
4) We reduce floor space area at much extent
5) We reduce cost of separate machine
6) We increase efficiency

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7. ACTIVITY CHART

Sr. Aug Sept- Oct Nov Dec Jan Feb- Mar Apr May
No Activity Plan -18 18 -18 -18 -18 -19 19 -19 -19 -19
Decision of
1 Work

2 Topic Selection
3 Data Collection
Literature
4 Survey

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Design
5 Calculation

6 Fabrication
Validation Of
7 Result

8 Report making

Work Completed

Work Remaining

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