International Journal of Pure and Applied Mathematics

Volume 114 No. 9 2017, 465-475

ISSN: 1311-8080 (printed version); ISSN: 1314-3395 (on-line version)
url: http://www.ijpam.eu
Special Issue
ijpam.eu

DESIGN AND ANALYSIS OF PUSH ROD ROCKER

ARM SUSPENSION USING MONO SPRING

C.S.Vishnu1N.PraveenKumar2

K.SomeswarRao3G.VVSV.Prasad4

K.Koshore5M.jaswanrh Sai6

123456 Department of Mechanical.

K L University, guntur,
522502, INDIA
[email protected]

Abstract
The main objective of this paper is to brief about mono spring rocker arm front
suspension which is a semi independent suspension system. The main criterion of
this project is to design a suspension system practically to a student formula hybrid
vehicle. The dynamic loads are to be considered for the design of wheel assembly,
frame, transmission, steering and braking systems, now loads are distributed to
front and rear side. The stiffness of the spring is calculated by considering front
loads. The design of the spring, damper, rocker arms and push rod was done by
SOLID WORKS software. Later on the assembly of all parts and mono spring
rocker arm front suspension system were designed. Analysis was done in LOTUS
SHANK SUSPENSION ANALYSIS SOFTWARE, from the analysis the designs are
said to be suitable for the end application.

AMS Subject Classification: 55P40, 97G80

Key Words: Mono spring, front suspension, stiffness, rocker

arm, push rod.

1 Introduction
1.1. SUSPENSION

Main function of suspension is to reduce the vibrations and shocks

that are occurring due to the irregularities on the road surface and to
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protect the passengers and goods. Suspension is used to maintain the

steering stability of vehicle by increasing the friction between roads
and tire surface and also to maintain good road handling by
maximized contact between road and wheels of vehicle. One of the
main function is to maintain all the steering parameters like camber,
caster, toe in and out, kingpin inclination etc. and as we are going to
design it for a formula hybrid car these parameters should be
considered to maintain directional stability and rolling resistance.

1.2. TYPES OF SUSPENSION

Three type suspensions are independent, dependent and semi-

independent. In This suspension consider it as semi-Independent.

2 Design of suspension system

2.1. Selection of material

The below Table 1 shows the properties of the material which are
used in designing of the suspension parts.

Table 1: Properties of materials

Properties (A-arms and push (Rocker arms using
rod material)
Using material)

Materials MILD STEEL(AISI Aluminium (6061

1018) T6)
Poisson’s ratio 0.29 0.33
Ultimate Tensile 440 310
strength (MPa)
Yield Tensile strength 370 276
(MPa)
Modulus of elasticity 205 68.9
(GPa)
Percentage of 15 12
elongation
Density (g/cc) 7.87 2.7

2.1.1. A-arms and Push Rod

• Mild steel -AISI 1018 material is used to design of the A-arms
and push rod because these parts required more strength. It is
cheaper in cost and provides more strength, toughness and
ductility. Moreover AISI 1018 have good weld ability.
• Mild steel-AISI 1045 material also more strength compare to
MS-AISI 1018 because more carbon percentage available in
AISI 1045 and weld ability is low compare to AISI 1018. (AISI
1018) material cost is low as compared to AISI 1045
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• Chromoly material is more strength but very high cost as

compared to MS-AISI 1018 & MS-AISI 1045. Hence Mild steel -
AISI 1018 is selected as the material for A-arms & push rod.

2.1.2. Rocker arm

• Aluminium-6061 T6 material is used to design the rocker arms

because rocker arm required more strength, corrosion
resistance and joining characteristics.
2.1.3. Spring
• Chrome silicon material used to design of the spring because
spring required more stiffness, elastic, flexibility and
absorbing the vibrations .chrome silicon have different
properties. They are Density = 7.86 g/cc, Modulus of
elasticity = 206.842 GPa, Minimum tensile strength = 235-
300 psi * (103) or 206.842 MPa

2.2. Roll centre analysis

Roll centre plays a important role in design of a suspension system.
Roll centre is a point at the centre line of vehicle around which the
vehicle rolls on its suspension, by combining both the roll centres at
front and back roll axis is formed. These are determined by the
instant centre of rotation it is a point where it forms a pivot point
between two links.
So, the roll centre is determined by projecting lines from instant
centre to the centre of tire ground contact so this is done on each side
of wheel from the front view and these both lines intersect at a point
in the centre of the vehicle line that intersecting point is the roll
centre of that specific front or back axle. To determine roll centres we
have to fix wishbone lengths, track width, tie rod lengths.

2.3. Design of spring

Before designing the spring have to assume some values basing on
type of vehicle that is fabricated and through that have to find out
the stiffness of the spring.
Dynamic loads considered are:
Weight at front side WF = 246.91lb
Weight at rear side WR = 370.37lb
Total weight WT = 617.29lb
Dimensions of vehicle:
Front track width tF = 4.66ft
Rear track width tR = 4.66ft
Wheel base l = 5.7ft
CG(Centre of gravity) height from ground, h = 0.833ft
Height from CG to Roll axis, H = 0.445ft
Assuming the side to side symmetry ride rate

ω= ½𝜋�
𝐾𝑅𝐹∗12∗32.2
𝑊2

1.55 = ½𝜋�
𝐾𝑅𝐹∗12∗32.2
=) KR = 28.37lb/in
𝑊2
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Where ωis the natural frequencies

the roll rates
12∗𝐾𝑅𝐹∗𝑡2𝐹
Kφ = = 3696.4lb-ft/rad
2
So that obtained all the required values for calculating the spring
stiffness.
𝐾𝑅𝐹∗𝐾𝑇
Wheel rate KW = = 29.19lb/in
𝐾𝑇−𝐾𝑅𝐹
The stiffness of the spring
KW = Ks(IR)2
KS = 116.76lb/in
By using stiffness values calculate the required no. of coils, mean
diameter of coil, coil diameter, and pitch of the spring
2.3.1Specifications of spring
Coil diameter, d = 8.8mm
Mean diameter, D = C*d = 79.2mm
To calculate no. of coils the below formula is used
𝐺∗𝑑^4
K=
8∗𝐷3 ∗𝑛
No. of active coils, na = 6
No. of inactive coils, nin = 2
Solid length, lsolid = 70.4mm
Free length, lfree = 188.3mm
pitch, = 31.3mm
spring travel, = 117.9mm

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3 Design of Assembly
3.1Solid works modelling
Solid works is modelling software which allows 3D- modelling and 2-
D drafting of elements. In order to perform the analysis of spring in
Ansys, it is necessary to model the spring in any of the modelling
software's such as Pro-Engineers, Catia or Solid Works, etc. We have
selected to use Solid works modelling software because of its
availability.

3.2. Push Rod

As the name in fig.2 push rod suggests which means it pushes the
rocker arm when bump occurs. Using this we can also adjust the ride
height of the vehicle.

Fig.2 Push Rod

3.3Rocker Arm
Fig.3 rocker arm is which transmits motion from the tire to the
spring with the help of push rod .where as using this can maintain
the motion ratio required for the vehicle and also helps to reduce
aerodynamic drag occurred due to the spring in formula cars.

Fig.3 Rocker Arm

3.4. Spring and Damper

As of in Fig.4 spring and Damper is used to absorb heavy shocks and
damp shock impulses. Where as only spring can absorb vibrations
but it cannot be stiff while damping, so to control the damping
damper is used in it. It helps in improved ride quality and handling
while travelling on a rough road.

Fig.4 spring and Damper

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4 Analysis in ansys software

4.1. Analysis of Spring
Ansys is engineering simulation software (computer-aided
engineering). Various types of analysis like structural analysis,
thermal analysis, etc are possible using Ansys analysis software. In
structural analysis in Ansys, boundary conditions are to be defined in
order to determine the stress and deflection. After modelling the
spring in Solid works modelling software, these models were
imported into Ansys Analysis Software. Various boundary conditions
and load cases were applied for determining the maximum stress and
maximum deflection for Spring.

4.1.1. Displacement and Maximum Shear Stress

By doing analysis on the spring that is designed with certain
specifications so by applying the un-sprung mass felt on the front
side on the spring some deformation occurs which is illustrated in
Fig.5 and Fig.6 indicates the Maximum shear stress occurred in the
spring. Where as Table 2 shows the parameters and obtained values
of spring.

Table 2: Analysis of Spring

Parameters Value
Maximum Force 1300 N
Maximum Deflection 63.134 mm
Maximum Shear Stress 353.95 mpa

Fig.5Total Deformation

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Fig.6 Maximum Equivalent elastic stress

5 Simulation using Lotus Suspension Analysis software

Lotus Engineering Software has been developed by Lotus automotive
company, using them on many power train and vehicle projects at
Lotus over the past 15 years. It offers simulation tools which enable
the user to generate models very quickly, using a mixture of
embedded design criteria and well-structured interface functionality.

5.1. Suspension geometry in lotus

Lotus simulation software has been used to simulate the suspension

geometry of Mono shock front suspension system. Various co-
ordinates of the entire system that is modeled in design software are
given as input which are called as hard points and the virtual model
is built. It looks like as shown in fig.7:

Fig.7 Suspension geometry in lotus

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5.2 Plot of camber angle

Fig.8 shows the change in camber angle for a rebound and bump for
the particular design of the suspension model where the camber is
between -2.5 to 2.5.

Fig.8 Graph plot between camber and bump

6 CONCLUSION
Mono shock front suspension system for a formula car is practically
designed and observed how it works. Analysis is done on every part
of the system. It resulted that good handling, good suspension travel
and it also reduces the un-sprung mass. The main disadvantage is as
the spring is mounted between two rocker arms directly while
cornering it is not able to retain the wheels straight as the load is
transferring to one side while cornering.
The future work can be done: Suspension system should be further
modified by adding a buckling rod for the safety of the spring not to
buckle and also have to change the position of the spring for better
performance while cornering.

7 REFERENCE
[1] K. Kishore Kumar, K. Someswara Rao, Simulation and analysis of
suspension system of formula-1 vehicle under dynamic condition by
using CAD Tools, IJST,Vol-9, ISSUE-48, Dec-2016.

[2] Thomas D. Gillespie, “Fundamentals of Vehicle Dynamics”, SAE

Inc.

[3] William F. Milliken and Douglas L. Milliken, “Race Car Vehicle

Dynamics” SAE Inc.

[4] N.Vivekanandan “DESIGN, ANALYSIS AND SIMULATION OF

DOUBLE WISHBONE SUSPENSION SYSTEM” International
Journal of Mechanical Engineering, Volume 2, Issue 6, June 2014.

[5] V.B. Bhandari, “Machine Design”, McGraw Hill, 2012.

[6] Cossalter: Motorcycle Dynamics,

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Race Dynamics, Greendale, 2002.
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