Strength Validation of Two-Wheeler Suspension System using SolidWorks

This project presents a comprehensive analysis of a two-wheeler front suspension system, focusing on validating its strength under various loading conditions. The analysis utilizes SolidWorks simulation software to assess the deformation, factor of safety, fatigue stress, and von Mises stress of the suspension system components. The report includes detailed model information, study properties, material properties, contact information, and mesh information for each component, including the attachment, spring, and damper inlet. The simulation results provide insights into stress distribution, displacement, and strain, along with fatigue check plots and design insights. The study employs static analysis to evaluate the performance of the suspension system, with the spring analysis utilizing Beryllium Copper and the attachment and damper inlet utilizing AISI 1035 Steel. The project concludes with a SolidWorks FloXpress report and a summary of the findings, demonstrating the importance of suspension system design for vehicle stability and passenger comfort.

Contents
Abstract.....................................................................1
Introduction..............................................................1
Literature review.......................................................1
Analysis reports.........................................................2
Simulation of Attachement......................................................................................................................2
Model Information.......................................................................................................................................................4
Study Properties.......................................................................................................................................................... 6
Units.............................................................................................................................................................................7
Material Properties......................................................................................................................................................7
Contact Information.....................................................................................................................................................9
Mesh Information......................................................................................................................................................10
Resultant Forces........................................................................................................................................................ 12
Study Results..............................................................................................................................................................13
Simulation of Spring..............................................................................................................................18
Model Information.....................................................................................................................................................19
Study Properties........................................................................................................................................................ 20
Units...........................................................................................................................................................................20
Material Properties....................................................................................................................................................21
Mesh Information......................................................................................................................................................23
Resultant Forces........................................................................................................................................................ 24
Simulation of Damper inlet........................................................................................................................................32
Model Information.....................................................................................................................................................33
Study Properties........................................................................................................................................................ 34
Units...........................................................................................................................................................................35
Material Properties....................................................................................................................................................35
Mesh Information......................................................................................................................................................37
Resultant Forces........................................................................................................................................................ 39
Study Results..............................................................................................................................................................39
SolidWorks FloXpress Report.................................................................................................................44
Results and conclusion............................................46

Abstract
It is proved that there is constant growing interest for providing improved performance of two
wheeler suspension systems, especially in past 2 decades suspension system of vehicle have
many functions like for supporting weight of vehicle, for providing the effective isolation of
chassis from excitations of road and maintaining contact of tires with ground and for maintaining
wheels of vehicle in appropriate position on surface of road. Suspension system of vehicle plays
a very important role for providing improved and stable suspension performance of the vehicle.
In these papers two wheeler front suspension system is analyzed for validating strength of
suspension system. Suspension system deformation, factor of safety, fatigue stress plot, von
misses’ stress is checked under loading conditions.
Introduction
Suspension system of vehicle plays an important role for providing guaranteed stability and
improved of performance of vehicle. In addition of these performances, suspension system of
vehicle provides more comfort to the passenger and also ensures other performance of
suspension like isolating passengers from the road from induced shocks and vibrations.
Therefore control design problem of the proper active vehicle suspension system is a very
important topic of research for achieving the required performance of vehicle suspension system.
It is very important to consider the three major suspension performances while designing those
are ride comfort that is related to the acceleration of vehicle. Road handling that is associated
with sprung mass which cause contact between tire and ground surface and deflection of
suspension system. These all are correlated to each other.
Literature review
Literature survey was conducted mainly to focus on designing on spring of suspension system
for increasing performance of suspension system. Spring designed was varied which depends on
the spring parameters like wire diameter, number of turns, outer diameter and material of spring.
With research we found that current springs of automobile suspension system are made from
alloy of beryllium and copper. Hence in our study we used that material for spring to perform
force analysis. Stress and deflection of spring and two others parts of suspension system is

checked by means of performing analysis in analysis software Solidworks. By means of that
effective design was carried out for suspension system.
Analysis reports
Simulation of Attachement
Date: Sunday, November 19, 2017
Designer: Solidworks
Study name:Static 2
Analysis type:Static

Model Information
Model name: Attachement
Current Configuration: Default
Solid Bodies
<L_MdInf_SldBd_Nm/> Treated As Volumetric Properties Document Path/Date
Modified
Imported4
Solid Body
Mass:0.0122656 kg
Volume:1.5625e-006 m^3
Density:7850 kg/m^3
Weight:0.120203 N
Imported5 Solid Body Mass:0.0122656 kg
Volume:1.5625e-006 m^3
Density:7850 kg/m^3

Weight:0.120203 N
Imported3
Solid Body
Mass:0.0122656 kg
Volume:1.5625e-006 m^3
Density:7850 kg/m^3
Weight:0.120203 N
Revolve2
Solid Body
Mass:0.591876 kg
Volume:7.53982e-005 m^3
Density:7850 kg/m^3
Weight:5.80039 N
Imported6
Solid Body
Mass:0.0122656 kg
Volume:1.5625e-006 m^3
Density:7850 kg/m^3
Weight:0.120203 N
Fillet2
Solid Body
Mass:1.56469 kg
Volume:0.000199324 m^3
Density:7850 kg/m^3
Weight:15.334 N
<L_MdInf_ShlBd_Nm/>
<L
_MdIn_ShlBd_Fr/>
<L
_MdInf_ShlBd_VolProp/>
<L
_MdIn_ShlBd_DtMd/>
<L_MdInf_CpBd_Nm/> <L_MdInf_CompBd_Props/>

<L_MdInf_BmBd_Nm/>
<L
_MdIn_BmBd_Fr/>
<L
_MdInf_BmBd_VolProp/>
<L
_MdIn_BmBd_DtMd/>
Study Properties
Study name Static 2
Analysis type Static
Mesh type Solid Mesh
Thermal Effect: On
Thermal option Include temperature loads
Zero strain temperature 298 Kelvin
Include fluid pressure effects from
SolidWorks Flow Simulation
Off
Solver type FFEPlus
Inplane Effect: Off
Soft Spring: Off
Inertial Relief: Off
Incompatible bonding options Automatic
Large displacement Off
Compute free body forces On
Friction Off
Use Adaptive Method: Off
Result folder SolidWorks document (c:\users\family\appdata\
local\temp)

Units
Unit system: SI (MKS)
Length/Displacement mm
Temperature Kelvin
Angular velocity Rad/sec
Pressure/Stress N/m^2
Material Properties
Model Reference Properties Components
Name: AISI 1035 Steel (SS)
Model type: Linear Elastic Isotropic
Default failure criterion: Unknown
Yield strength: 2.82685e+008 N/m^2
Tensile strength: 5.85e+008 N/m^2
Elastic modulus: 2.05e+011 N/m^2
Poisson's ratio: 0.29
Mass density: 7850 kg/m^3
Shear modulus: 8e+010 N/m^2
Thermal expansion
coefficient:
1.1e-005 /Kelvin
SolidBody 1(Imported4)
(Attachement),
SolidBody 2(Imported5)
(Attachement),
SolidBody 3(Imported3)
(Attachement),
SolidBody 4(Revolve2)
(Attachement),
SolidBody 5(Imported6)
(Attachement),
SolidBody 6(Fillet2)
(Attachement)
Curve Data:N/A
Loads and Fixtures
Fixture name Fixture Image Fixture Details
Fixed-1
Entities: 2 face(s)
Type: Fixed Geometry
Resultant Forces
Components X Y Z Resultant

Fixture name Fixture Image Fixture Details
Reaction force(N) -0.0132675 -999.898 -0.0598593 999.898
Reaction Moment(N.m) 0 0 0 0
Load name Load Image Load Details
Force-1
Entities: 1 face(s)
Type: Apply normal force
Value: 1000 N

Contact Information
Contact Contact Image Contact Properties
Contact Set-1
Type: Bonded contact
pair
Entites: 2 face(s)
Global Contact
Type: Bonded
Components: 1 component(s)
Options: Compatible
mesh

Mesh Information
Mesh type Solid Mesh
Mesher Used: Curvature based mesh
Jacobian points 4 Points
Maximum element size 9.32822 mm
Minimum element size 0.466411 mm
Mesh Quality High
Mesh Information - Details
Total Nodes 97222
Total Elements 52643
Maximum Aspect Ratio 19.953
% of elements with Aspect Ratio < 3 84.7
% of elements with Aspect Ratio > 10 0.0304
% of distorted elements(Jacobian) 0
Time to complete mesh(hh;mm;ss): 00:00:15
Computer name: JKMRS

Mesh Control Information:
Mesh Control Name Mesh Control Image Mesh Control Details
Control-1
Entities: 1 Solid Body (s)
Units: mm
Size: 4.66411
Ratio: 1.5