Adama Science and Technology University

School Of Mechanical, Chemical and Material Engineering

Department Of Mechanical System and Vehicle Engineering
Course Title:- Research methodology
Title:- Failure analysis of suspension/coil spring

Prepared by Jatema Abera

ID NUM:- pge/28441/15
 Abstract

Due to frequent failures of coil springs on a specific type of motor vehicle, analysis of
possible causes of failures was performed.
 several other experimental techniques were used in the failure analysis
 several other experimental techniques were used in the failure analysis
 Suspension system plays an important role in vehicles.
 It is used to damp shock impulse:-
 dissipate kinetic energy (KE)
 as well as the suspension carries the vehicle body and transmits all the force between the
road and body
 make comfort in driving and safety
 Suspension system have four types, such as: -
• leaf spring
• coil spring
• and torsional bar
• shock absorber
 Introduction

Failure analysis of coil spring is done to reduce the risk

happened on human beings and wealth’s.
The failure of suspension system are many causes :-
• lack of material selection
• limiting selected material mostly on steel
• copper alloy
• carbon composite
• no experiment was done on tensile and compression test
• no stress calculation
• lack of good experimental processes
 Hypothesis

Hypothesis: - reducing the failure caused due

to unbalanced load applied on suspension
system
• When the load applied is not balanced with carrying
body the failure can occur on suspension system and
body of vehicle .
• To minimize the load, we have to analysis all the force
applied on the bodies.
 Statement of the problem
I have seen many problems from previously Reviewed papers on Failure Analysis of suspension
system
The previous paper are analyses on limited Number of applied force that cause failures:-
 less experimental test
 small types of material
 only reducing the weight of suspension system
 only on the wear
 There is no test on mechanical properties of materials with the modified weight
like:-
 strength
 hardness
 ductility
 toughness
 what kind of lubrication the selected material used
 also, we have to check tensile, torsional and compression test properties of material.
 Objectives of study
General Objectives: - Reviews on failure Analysis of Suspension system to reduce
the dangerous causes on Human being and Wealthy.
Specific objectives: -
 To make balanced applied force on the suspension system.
 To take full experimental on mechanical properties
 To get resonance formed
 To analysis Stress concentration.
 Methodology

By assessing existing reviewed paper, through

collecting relevant data’s
making a through strength analysis of all load carrying
elements
by selecting suitable source materials considering all
the economic, ergonomic and safety characteristics
make balance force applied on the suspension system
by using ANSYS software.
 Literature Review
Current lightweight design of suspension is mainly focused on the component design phase.
From the literature review it reveals: -
proposing a design frame work for conduct the lightweight design in the layout design stage
of suspension system.
Carrying out specific design for vehicle height adjustment system (VHAS)
Problem of the review: - it deals only on the reducing weight but there is no consideration
of other causes that may cause failure, like:-
 mechanical properties of material:-
 hardness
 brittleness
 Strength
 toughness
 Malleability
 less experimental test
 Suspension system
Suspension system are parts that is used to carry
load and make comfortable for the passenger in
automobile.
Functions of suspension system:-
 To safe guard passengers and goods against road shocks
 To preserve the stability of vehicles while in motion
 To provide the wheels always in contact with road while
driving cornering and braking
 To maintain proper steering geometry
 To provide suitable riding and cushioning properties
 To Allow rapid cornering without extreme body roll
 .

Coil spring:- is the most common type of

spring found on modern vehicles.
Coil springs are made of special round
spring steel wrapped in a helix shape. The
strength and handling characteristics of a
coil spring depend on the following:-
 Coil diameter
 Number of coils
 Height of spring
 Diameter of the steel coil that forms the
spring
Leaf springs :- Leaf springs are now limited to
the rear of some cars.

Figure 2 Suspension system of

coil spring and leaf spring
 Definitions of the Some Terms Used in Compression Coil
Springs

Solid Length:- That is the length when the spring is compressed until the
 

coils come in contact with each other

• Ls = n’. d
Free length:- It is the length of the spring in the free or unloaded
condition.
• LF = n’. d + δmax + 0.15δmax

Figure 3 Free and Solid Length of the Helical Coil

Spring
Work Plan
 Cost Estimation
Cost of analysis include the cost of material for experiment test,
cost of standard materials available in market.
Cost of materials (𝑪𝒎)
The cost of the materials is bought and sold in 𝐾𝑔. The formula of
the cost analysis is as follows: -
𝑇𝑜𝑡𝑎𝑙 𝑐𝑜𝑠𝑡 in = [𝑑𝑖𝑟𝑒𝑐𝑡 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙 𝑐𝑜𝑠𝑡] + [𝑑𝑖𝑟𝑒𝑐𝑡 𝑙𝑎𝑏𝑜𝑟 𝑐𝑜𝑠𝑡] +
[𝑑𝑖𝑟𝑒𝑐𝑡 𝑒𝑥𝑝𝑒𝑛𝑠𝑒] + [𝑜𝑣𝑒𝑟ℎ𝑒𝑎𝑑 𝑐𝑜𝑠𝑡 𝑚𝑎𝑛𝑢𝑓𝑎𝑐𝑡𝑢𝑟𝑖𝑛𝑔] +
[𝑎𝑑𝑚𝑖𝑛𝑖𝑠𝑡𝑟𝑎𝑡𝑖𝑣𝑒 𝑂𝐻𝐶]
𝐷𝑖𝑟𝑒𝑐𝑡 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙 𝑐𝑜𝑠𝑡:− is the cost of raw material before it
proceeds into the machine/as it is. To calculate we must now the
dimensions or the weight of the raw material.
 Continue….
𝐷𝑖𝑟𝑒𝑐𝑡 𝑙𝑎𝑏𝑜𝑟 𝑐𝑜𝑠𝑡 (𝐷𝐿𝐶): - is the cost of technicians/machinist that operates
the materials into the required shape or designed. Office workers and the
person who see the finished material is not the 𝐷𝐿𝐶.
𝐷𝑖𝑟𝑒𝑐𝑡 𝑒𝑥𝑝𝑒𝑛𝑠𝑒 𝑐𝑜𝑠𝑡: - assume there is no direct expense in our design.
𝑀𝑎𝑛𝑢𝑓𝑎𝑐𝑡𝑢𝑟𝑖𝑛𝑔 𝑜𝑣𝑒𝑟ℎ𝑒𝑎𝑑 𝑐𝑜𝑠𝑡 (𝑀𝑓𝑔 𝑂𝐻𝐶):- is indirect cost like cost of
machine depreciation, cost of materials used for our machine that operates
our work pieces like rag, coolant (grease, oil and) and etc.
The total cost (𝑇𝑐) is the summation of the above in ETB
 Recommendation
• The chemical composition of the material was analyzed by standard
atomic absorption spectroscopy method. All Mechanical properties
of material was tested by compression, torsional and tensile test
machine. near to machines using software like ANSYS are also
analysis stress, strain, torsional and shear (deformation, principal
and concentration). We have to use X-ray and scanning microscopy
to check inherent crack. In this paper no experimental was done due
to lack of machine/materials. Any person can do all the left works or
the limitation of the reviewed paper written on draw backs.
Generally, by using many types of machines and doing real
experiment we can improve the efficiency of the spring suspension
system.
 Conclusion
• Suspension system plays an important role in vehicles. It is used to damp shock
impulse, dissipate kinetic energy (KE), make comfort in driving and safety. as well as
the suspension carries the vehicle body and transmits all the force between the road and
body. Suspension system have four types, such as: - leaf spring (for heavy loads), coil
spring (for light load/vehicle), shock absorber and torsional bar. The failure of
suspension system are many causes lack of material selection, limiting selected material
mostly on steel, copper alloy, and carbon composite, lack of good experimental
processes, no stress calculation(identified), no experiment was done on tensile and
compression test.
• reviews are considering mostly on the design of reducing the weight of suspension
system, less experimental test. There is no test/compare mechanical properties of
materials with the modified weight like strength, hardness, ductility, toughness, what
kind of lubrication the selected material used and no surface modification. also, we
have to check tensile, torsional and compression test properties of material. suspension
system mostly used for damp/ dissipating shock energy.
 Reference
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a
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