UNIT-6

1.Steering System
2.Suspension System
3.Braking System
By:
V. Rama Devi
Assistant professor
Department of Mechanical Engineering
 SYLLABUS
• Steering System : Steering geometry
• – camber, castor, king pin rake,
• combined angle toeing,
• center point steering.
• Types of steering mechanism
• – Ackerman steering mechanism,
• Davis steering mechanism,
• steering gears – types, steering linkages.
 Objectives:

• Objectives:
• By going through the various sections of this unit, one
should be able to
• understand about the steering systems like Ackerman
steering mechanism, davis steering mechanism,
linkages in steering
• Explain about the suspension system like torsion bar,
shock absorbers etc
• Gain knowledge about Braking systems – mechanical,
hydraulic, pneumatic
 Contents
• Identify the functions and requirements of the steering
system of an automobile

• Explain how toe, camber, caster, axle inclination, turning

radius, and axle alignment affect tire wear, directional
stability, and handling.

• Ackerman steering.

• Davis steering mechanism

• steering gears and steering linkages

 Steering system
• A mechanism that enables the driver to control the direction of the vehicle
travel.
• Components:
Steering wheel, rod, pit man arm, steering gear box, tie rod
• What is the function of steering system?
• The function of a steering system is to convert the rotary movement of the
steering wheel in driver's hand into the angular turn of the front wheels on
road.
• What are the different types of steering systems?
• There are three basic types of power steering systems found in vehicles: the
hydraulic power steering (HPS), the electric power hydraulic steering (EPHS),
and the fully electric power steering (EPS). Electric and electronic power
steering both refer to the same system.
 Functions
• Functions - Primary
• To achieve angular motion of front wheels to negotiate a
turn.
• Done through Steering linkage and Steering gear ( convert
rotary motion of the steering wheel into the angular motion
of the front road wheels)
• Functions - Secondary
• Directional stability of the vehicle when going straight ahead
• Perfect rolling motion of wheels at all times
• Provide straight ahead recovery after completing a turn
• To minimize the tyres wear
 Steering Systems
• Front wheel steering system
• All wheel steering system

Requirements
• very accurate and easy to handle
• Effort required to steer should be minimal
and must not be tiresome to driver
• Directional stability
 Front Axle
• Not used in modern cars
• But continued to be used in heavy trucks
• 0.4 % Carbon Steel & 1.3% Nickel Steel
• Bending loads ( weight of the vehicle)
• Torque loads ( due to braking)
• Main axle beam is connected to stub axles by
means of King Pins
Front Axle
Front Axle

T – shaped
Knuckles on
both the ends
Steering Knuckle with Reverse Elliot Axle

Steering Knuckle is fitted to

Reverse Elliot Axle with the
help of king pin and bushes

Stub Axles made up of 3%

Ni, Cr-Mb Alloys
Hub fitted with Stub Axle
King pin or Knuckle Pin

 Steering knuckles mount to the

front axle by kingpins or knuckle
pins.
 Kingpins provide the ability to
steer the vehicle.
 Spindle
 The steering knuckle
incorporates the spindle onto
which wheel bearings and
wheel hubs are mounted, plus a
flange to which the brake spider
is bolted.
 A steering control arm is attached
to the left side steering knuckle.
Steering Mechanism
Steering Mechanism
 Rack and Pinion Steering Gears

-Used in Power Steering

-Simple and Light
-Small Space
-Less linkage components are used
-Steering column pinion meshes with the rack.
-When steering wheel is rotated pinion turns and
moves the rack to left and right
-Movement of rack is further relayed through ball
joints and tie rods to the stub axles for the front
wheel to be steered
Power Steering

Tyres of wider section greater

contact to ground
So, greater force for steering
cars and heavy vehicles under
turns
Power steering provides
automatic hydraulic
assistance to manual steering
Operated by fluid under
pressure
Power Steering Types

Integral type
Power Steering assembly is integral part of
steering gear

Linkage Type
Part of linkage
Integral Power Steering
Integral Power Steering
Integral Power Steering
Integral Power Steering
Power Steering Types – Steering Gear Type

 Power steering gears are similar to a manual

recirculating ball steering gear with the addition
of a hydraulic assist control mechanism.
 The power steering gearbox is charged with
hydraulic fluid under pressure and uses a rotary
control valve to control the flow of fluid.
 The movement of the ball nut is assisted by
hydraulic pressure.
 The integral-type power steering has the rotary
control valve and a power piston integrated with
the gearbox.
 The rotary valve directs the oil pressure to the
left or right chamber to steer the vehicle.
 The spool valve is actuated by a lever or a small
torsion bar located in the worm gear.
Hydraulic Operation

 The rotary control valve is an open-center type that allows a continuous flow of oil
when held in the neutral position by the torsion bar.
 When steering effort is applied, the spring action of the torsion bar results in the
input shaft rotating slightly in advance of the ball screw.
 The six pairs of grooves that form the rotary control valve are displaced from their
neutral flow position.
 As steering effort increases, so does the amount of displacement.
 Depending on the direction steered, the groove displacement of the input shaft
directs hydraulic oil through the appropriate drilled passages in the ball screw to one
side or the other of the piston.
 Camber
• Steering tires also are designed to use a positive
camber angle setting.
• Camber is a measure of the angle a wheel leans
away or toward the frame.
– Positive camber means that the tires lean away
from the truck frame at the top.
– A positive camber setting is used to help
compensate for that slight tendency of steering
tires to toe-out when the vehicle is moving.
 Camber
 Excessive positive camber
causes the tire to wear on its
outside shoulder.
 Excessive negative camber
causes the tire to wear on its
inside shoulder.
 Unequal camber in the front
wheels also can cause the
steering to lead to the right or
left.
 The truck will lead to the side
that has the most positive
camber.
 Toe (1 of 2)

 The ideal toe angle when a vehicle is running loaded down a

highway is zero.
 We set toe angles statically.
 The objective of setting toe at a specified angle when
aligning the front end is to have zero toe at highway
speeds.
 Toe (2 of 2)
 Incorrect toe angles not only accelerate tire wear but also can
have an adverse effect on directional stability of the vehicle.

 Incorrect toe angles have the potential to cause more front tire
Toe (2 ofany2)other incorrect alignment angle.
wear than

 Too much toe-in produces a scuffing, or a featheredge, along the

inner edges of the tires.

 Excessive toe-out produces a similar wear pattern along the outer

edge of the tires.

 When a fully loaded vehicle is moving at highway speeds, there is

a slight tendency of steering tires to toe-out.

 Any looseness in the steering linkage and tie-rod assembly also

will contribute to the toe-out tendency.
KPI
Toe In and Toe out
Steering Mechanism
Steering Mechanism
Ackermann Steering

As a result of track width, the tires on the inside and

outside of a vehicle in a turn roll on different radii.
A vehicle with Ackermann steering will produce
differing steer angles. The inside tire is steered at a
greater angle than the outside tire of the steered axle if
Ackermann steer is achieved.
Varying amounts of Ackermann are achieved and are
presented as a % of true (100%) Ackermann.
Design Considerations

Track width and wheel base length, from a design point,

are the fundamental vehicle variables in determining
Ackermann.
Ackermann is achieved through steering arm angles, tie
rod angles and selected other variables.
Front steer vehicles (steering in front of the axle) tend to
have greater restriction on the availability for Ackermann
correction.
Tire selection and vehicle goals may determine final
Ackermann goals.
Ackermann Steering Mechanism
Ackermann Steering Mechanism
Ackermann Steering Mechanism
DAVIS STEERING MECHANISM
DAVIS STEERING MECHANISM
SUMMARY
Automobile Suspension System
Suspension System : syllabus
- Objects of suspension systems
– rigid axle suspension system,
- torsion bar,
- shock absorber,
- Independent suspension system.
PURPOSE OF THE SUSPENSION SYSTEM

As we review suspension system components and how they work

together, remember that a vehicle in motion is more than wheels
turning.
As the tire revolves, the suspension system is in a dynamic state of
balance, continuously compensating and adjusting for changing
driving conditions. Today's suspension system is automotive
engineering at its best.

What is the function of the suspension system?

The primary functions of the suspension system include
maximizing the contact between the tires and the road surface,
providing steering stability and good handling, evenly supporting
the weight of the vehicle (including the frame, engine, and body),
and ensuring the comfort of passengers by absorbing and
dampening ...
The components of the suspension system perform six
basic functions:

1. Maintain correct vehicle ride height

2. Reduce the effect of shock forces
3. Maintain correct wheel alignment
4. Support vehicle weight
5. Keep the tires in contact with the road
6. Control the vehicle’s direction of travel
However, in order for this to happen, all the suspension
components, both front and rear, must be in good
working condition.
 Function Suspension System
•Supports the weight.

•Provides a smooth ride.

•Allows rapid cornering without extreme

body roll.

•Keeps tires in firm contact with the road.

•Prevents excessive body squat.

•Prevents excessive body dive.

•Allows front wheels to turn side-to-side for steering.

•Works with the steering system to keep the wheels in correct alignment.
 Suspension System Parts
Basic Parts: Main components of a moving vehicle
suspension system are the Struts, Shock
Absorbers, Springs and Tires

1.Control arm–
movable lever that fastens
the steering knuckle to the vehicle’s
body or frame.

2.Steering Knuckle – provides a spindle or

bearing support for the wheel hub, bearings
and wheel assembly.
Suspension System Parts
Suspension System Parts
TYPES OFSUSPENSION SYSTEM
 Types of Suspension System

Non independent

Independent

1.Non-independent/Rigid suspension has both right and left wheel attached

to the same solid axle. When one wheel hits a bump in the road, its upward movement
causes a slight tilt of the other wheel.

2.Independent suspension allows one wheel to move up and down with minimal
effect to the other.
 Suspensions

Independent

Nonindependent
 Suspension System

Coil spring is the most common type of spring found on modern vehicles.

Leaf springs are now limited to the rear of some cars.

 Springs
• The springs support the weight of the vehicle,
maintain ride height, and absorb road shock.
Springs are the flexible links that allow the
frame and the body to ride relatively
undisturbed while the tires and suspension
follow the bumps in the road.
 Springs
• Springs are the compressible link between the frame
and the body.
• When an additional load is placed on the springs or the
vehicle meets a bump in the road, the springs will
absorb the load by compressing.
• The springs are a very important component of the
suspension system that provides ride comfort. Shocks
and struts help control how fast the springs and
suspension are allowed to move, which is important in
keeping tires in firm contact with the road.
 Bounce, Jounce
• During the study of springs, the term bounce refers
to the vertical (up and down) movement of the
suspension system.
• The upward suspension travel that compresses the
spring and shock absorber is called the jounce, or
compression.
• The downward travel of the tire and wheel that
extends the spring and shock absorber is called
rebound, or extension.
 Energy In the Spring
• When the spring is deflected, it stores energy.
Without shocks and struts the spring will extend and
release this energy at an uncontrolled rate.

• The spring's inertia causes it to bounce and

overextend itself. Then it recompresses, but will
again travel too far. The spring continues to bounce
at its natural frequency until all of the energy
originally put into the spring is used.
 Sprung and Un sprung weights
• Sprung weight is the weight supported by the springs. For
example, the vehicle's body, transmission, frame, and motor
would be sprung weight.
• Un sprung weight is the weight that is not carried by springs,
such as the tires, wheels, and brake assemblies.
• The springs allow the frame and vehicle to ride undisturbed while
the suspension and tires follow the road surface.
• Reducing un sprung weight will provide less road shock.
• A high sprung weight along with a low un sprung weight provides
improved ride and also improved tire traction.
 Types of Springs

A. Coil spring
B. Leaf spring
C. Air spring
D. Torsion bar
 A. Coil Springs
• The most commonly used spring is
the coil spring. The coil spring is a
length of round spring steel rod that is
wound into a coil. Unlike leaf springs,
conventional coil springs do not
develop inter-leaf friction. Therefore,
they provide a smoother ride.
• The diameter and length of the wire
determine the strength of a spring.
Increasing the wire diameter will
produce a stronger spring, while
increasing its length will make it more
flexible.
Coil Springs
Coil Spring
 Spring rate
• referred to as deflection rate, is used to measure spring
strength. It is the amount of weight that is required to
compress the spring 1 inch. For example: If it takes 100 lbs. to
compress a spring 1inch, it would take to 200 lbs. to compress
the spring 2 inches.

• Some coil springs are made with a variable rate. This variable
rate is accomplished by either constructing this spring from
materials having different thickness or by winding the spring so
the coil will progressively compress at a higher rate. Variable
rate springs provide a lower spring rate under unloaded
conditions offering a smoother ride, and a higher spring rate
under loaded conditions, resulting in more support and control.
 Springs’ failures

• Coil springs require no adjustment and for the most part

are trouble-free. The most common failure is spring sag.
Springs that have sagged below vehicle design height
will change the alignment geometry.
• This can create tire wear, handling problems, and wear
other suspension components.
• During suspension service it is very important that
vehicle ride height be measured.
• Ride height measurements not within manufacturer’s
specifications require replacement of springs.
 B. Leaf Springs
Leaf springs are designed two ways: multi-leaf and mono-leaf. The multi-leaf
spring is made of several steel plates of different lengths stacked together.

During normal operation, the spring compresses to absorb road shock. The leaf
springs bend and slide on each other allowing suspension movement. An example
of a mono-leaf spring is the tapered leaf spring.

The leaf is thick in the middle and tapers toward the two ends. Many of these leaf
springs are made of a composite material, while others are made of steel. In most
cases leaf springs are used in pairs mounted longitudinally (front to back).

However, there are an increasing number of vehicle manufacturers using a single

transverse (side to side) mounted leaf spring.
Leaf Springs
Leaf Spring
Leaf Spring
C. Air and gas springs
C. Air and gas springs
 Schematic view of Air
Suspension System

Location of Air bellows

Location of Air bellows in Heavy

Motor Vehicles
Advantages & Disadvantages of Air suspension
Advantages Disadvantages
•Variable space for wheel
deflection is put for optimum
•Higher initial cost
use for automatic height control
•Occupies more space.
•Head light alignment does not •Maintenance cost is more
vary due to different loading •Due lack of friction damping is
condition. necessary due road shock
•It improve the ride comfort.
•Reduce noise in suspension
system.

Applications:- Volvo Buses

D. Torsion bar
 Torsion Bar
• Definition: A steel bar that
is twisted to support the
weight of the vehicle.
Torsion bars are used in
place of coil or leaf springs
on some vehicles, and
allow ride height to be
adjusted to compensate for
sage that occurs over time.
 Torsion Bar
• The torsion bar is a straight or L
shaped bar of spring steel. Most
torsion bars are longitudinal,
mounted solidly to the frame at
one end and connected to a
moving part of the suspension at
the other.
• Torsion bars may also be transverse
mounted. During suspension
movement, the torsion bar will
twist, providing spring action.
 Torsion bar suspension
• Uses a torsion bar as its main weight bearing spring.
One end of a long metal bar is attached firmly to the
vehicle chassis; the opposite end terminates in a
lever, mounted perpendicular to the bar, that is
attached to a suspension arm, spindle or the axle.
• Vertical motion of the wheel causes the bar to twist
around its axis and is resisted by the bar's torsion
resistance. The effective spring rate of the bar is
determined by its length, diameter and material.
Torsion Bar
 Torsion bars
• Manufacturers change the torsion bar to adjust the
ride height to compensate for heavier or lighter
engine packages.
• It takes up less of the vehicle's interior volume
compared to coil springs
• A slight disadvantage is that torsion bars, unlike coil
springs, usually cannot provide a progressive spring
rate.
• Over-rotating the torsion bars can also cause the
suspension to hit the bump stop prematurely,
causing a harsh ride
Advantages & Disadvantages of Torsion bar suspension

Advantages Disadvantages
•It does not take accelerate &
•Light in weight. Braking thrust so required
•Less space additional linkages
•Due lack of friction damping is
occupies . necessary due road shock
•Its maintenance cost •
is less.
•Initial cost is less.
•Ride comfort is more.

Applications:-SUV Tata Safari, Tempo

Trax
Shock Absorber or Damper
Dampers
Dampers
Dampers
 We all have heard
about shock
absorbers. As the
name implies, it is
used to absorb
shocks occur
during driving on
uneven roads

https://youtu.be/Fd8Ng5ll9Jk
How do shock absorbers work?
a device that controls unwanted
spring motion through a process
known as dampening. Shock
absorbers slow down and reduce
the magnitude of vibratory
motions by turning the kinetic
energy of suspension movement
into heat energy that can be
dissipated through hydraulic fluid.
ADVANTAGES
This shock absorber is available in various
size according to the requirement.
Noise free operation
Less maintenance required.
Low manufacturing cost.
High operating speed.
1 Wishbone Suspension
The suspension must be
designed in such a way as to
keep the wheel upright for Upper wishbone
maximum tyre contact
(vehicle control) and to
minimize tyre wear.
The upper wishbone is
short and the lower
wishbone is longer.
Both wishbones pivot points
and lengths are calculated to
provide the best operating
angle for a given suspension
movement.
Lower wishbone
10 of 12
 Advantages & Disadvantages of
Wishbone type independent suspension
Advantages Disadvantages

•Ride quality is good. •Initial cost is more

•Maintenance cost is more.
•Improve the steering
•Required frequent wheel
preciseness since the
alignment otherwise increase
wheel movement are not
tyre wear.
link
•Ground clearance
increase

Applications:-SUV,CARS
2 MacPherson Strut
This is a very popular and efficient form of
suspension. It has one control arm and a strut
assembly. A coil spring and shock absorber Strut
will normally form parts of the strut assembly. assembly

Coil springs may be mounted on

Frame
the control arm instead of being
around the strut. On this type,
the shock absorber connects
Shock
the knuckle to the frame.
absorber

This type of suspension strut is Knuckle

often also used on rear
Control
suspension systems.
arm
Coil spring 12 of 12
Front Suspension
(MacPherson Strut)
MacPherson Strut Suspension
The top of the strut is bolted to
a reinforced section of the Steering knuckle
frame structure.

The lower end of the strut is

attached to a steering knuckle. Strut

The control arm is also attached

to the steering knuckle. Frame

The control arms are mounted on Control

a cradle section of the frame. arm

An anti-roll bar links the two Cradle

control arms together to reduce
sway (body roll). Anti-roll bar
14 of 12
Struts
 Advantages & Disadvantages of
Macpherson strut suspension
Advantages Disadvantages
•Light in weight. •Not suitable for Heavy motor
•Camber does not change due vehicle.
to up & movement of wheels •Load caring capacity is less.
•Maximum Engine compartment
available.
•Maintenance cost is less.
•Initial cost is less.
•Ride comfort is more.
•Improve road safety.

Applications:-CARS
 BRAKING SYSTEM
SYLLABUS
Mechanical brake system
Hydraulic brake system
Master cylinder,
wheel cylinder tandem master cylinder
Requirement of brake fluid,
Pneumatic and vacuum brakes.
 
Braking system
 The Importance & Function of Brake Fluid

•Brake fluid is a type of hydraulic fluid used in hydraulic brake and

hydraulic clutch applications in vehicles.
•It is used to transfer force into pressure, and to amplify braking force.
•Simply stated, when you apply your foot to the brake pedal, brake fluid
transfers this force into pressure to the front and rear brakes and stops
the vehicle. It works because liquids are incompressible.
•Brake fluid is designed to protect the metals used inside components
such as calipers, wheel cylinders, master cylinders, and ABS control
valves. The fluid must also protect against corrosion as moisture enters
the system. Additives (corrosion inhibitors) are added to the base brake
fluid to help accomplish this.