PROJECT

DESIGN AND ANALYSIS OF SHOCK ABSORBER

SUBMITTED TO:- SUBMITTED BY:-

Dr. Mohammad Taufik Mithun Yadav (201116263)

Dr. Sudhanshu Kumar Kalpak Kamble(201116221)

Asst. Proffessors Vivek Shah(201116245)

(Mech. Dept.) Vivek Kumar (201116265 )

PROJECT BASED PRODUCTION LAB ME(2410)

DEPRTMENT OF MECHANICAL ENGINEERING

MAULANA AZAD NATIONAL INSTITUTE OF TECHNOLOGY
BHOPAL , MADHYA PRADES
CONTENTS
1. Acknowledgement

2.Abstract

3. Why this project?

4. Introduction to CAD/CAM/CAE

5. Introduction to Creo

6. Introduction to Shock Absorber

7. Different Part of Shock Absorber

8.Functions of shock absorber

9. Conclusion
10.Reference

11.Roles
 1. ACKNOWLEDGEMENT

This is the golden and memorable day for me on which I am presenting our project report

entitled “DESIGN OF SHOCK ABSORBER USING CREO”, during our under

graduate level of engineering studies.

It’s our pleasure and fortune that, I avail this opportunity to place our profound gratitude to

Dr. Mohammad Taufik and Dr. Sudhanshu Kumar whose co-operation and guide helped

me to traverse a long distance and finally complete this project.

 2. ABSTRACT

-Shock absorber is a mechanical device designed to smooth out or damp shock impulse, and
dissipate kinetic energy. In a vehicle, it reduces the effect of traveling over rough ground,
leading to improved ride quality, and increase in comfort due to substantially reduced
amplitude of disturbance.

The model is also changed by changing the thickness of the spring. Structural analysis and
modal analysis are done on the shock absorber by varying different spring materials. Spring
materials are Spring Steel, Phosphor bronze, Beryllium Copper and Titanium alloy.

To validate the strength of the model, the structural analysis on the helical spring was done.
The analysis is done by considering loads, bike weight, and single, double riding. Modal
analysis is done to determine the displacements for different frequencies for number of
modes.
 3. WHY THIS PROJECT ?

From the very beginning of our engineering studies our dream is to envisage ourself as a
design engineer round the globe. Being a engineering student I have always keen interested
towards drawing and designing various field of mechanical engineering , our career
objectives include performing extensive research in mechanical engineering as a design
engineer being part of an organization which provide me ample opportunity to do so . I feel
that without a design project work our knowledge over CREO will remain incomplete, so I
decided to do this project work “DESIGN OF SHOCK ABSORBER ASSEMBLY USING
CREO”, with direct supervision in inspiration of our project guide Dr. Mohammad Taufik
and Dr. Sudhanshu Kumar As well as possible I try to explore our view and ideas Over the
subject. I may not certain about what new design I have done in this project but , but confirm
that what design I have done is a complete new experience for me and hope the experience
gain by me through this project work will help me to fulfill our dream . as possible as

every effort has been made by me to give a crystal clear view over the subject on reader’s
mind.
 4. INTRODUCTION TO CAD/CAM/CAE

The Modern world of design, development, manufacturing so on, in which we have stepped
can’t be imagined with out interference of computer. The usage of computer is such that,
they have become an integral part of these fields. In the world market now the competition in
not only cost factor but also quality, consistency, availability, packing, stocking, delivery etc.
So are the requirements forcing industries to adopt modern technique rather than local
forcing the industries to adapt better techniques like CAD / CAM / CAE, etc.

The Possible basic way to industries is to have high quality products at low costs is by using
the computer Aided Engineering (CAE), Computer Aided Design (CAD) And Computer
Aided Manufacturing (CAM) set up. Further many tools is been introduced to simplify serve
the requirement CREO, CATIA UG are some among many.
This penetration of technique concern has helped the manufacturers to

a) Increase productivity

b) Shortening the lead-time

c) Minimizing the prototyping expenses

d) Improving Quality

e) Designing better products

Here in this Chapter we will be discussing on STOP VALVE.

Section 1: Description of SHOCK ABSORBER and Its working principle

Section 2: Modelling of each disassembled parts and assembling

CAD: Computer Aided Designing (Technology to create, Modify, Analyze or Optimize the
design using computer.

CAE: Computer Aided Engineering (Technology to analyze, Simulate or Study behavior of

the cad model generated using computer.

CAM: Computer Aided Manufacturing (Technology to Plan, manage or control the

operation in manufacturing using computer.
4.1. NEED FOR CAD,CAM CAE : The usage of CAD CAE CAM have changed the
over look of the industries and developed healthy standard competition , as could achieve
target in leantime and ultimately the product reaches market in estimated time with better
quality and consistency

. In general view, it has lead to fast approach and creative thinking.

2. ADVANTAGES:

1. Cut off of the designing time

2. Cut off of the editing time

3. Cut off of the manufacturing time

4. High controlled quality

5. Reduction of process cost

6. Consistency

3. DRAWBACKS:

1. Requires skilled operators

2. Initial setting assumption consumes time

3. Setting cost is more

4. Over heads are high

 5. INTRODUCTION TO CREO

INTRODUCTION CREO is a robust application that enables you to create rich and
complex designs. The goals of the CREO course are to teach you how to build parts and
assemblies in CREO, and how to make simple drawings of those parts and assemblies. This
course focuses on the fundamental skills and concepts that enable you to create a solid
foundation for your designs.

WHAT IS CREO??? CREO is mechanical design software. It is a feature-based, parametric

solid modelling design tool that takes advantage of the easy-to-learn Windows graphical user

interface. You can create fully associative 3-D solid models with or without constraints while

utilizing automatic or user-defined relations to capture design intent. To further clarify this

definition, the italic terms above will be further defined:

FEATURE BASED
Like an assembly is made up of a number of individual parts, a CREO document is made up of individual
elements. These elements are called features.

When creating a document, you can add features such as pads, pockets, holes, ribs, fillets, chamfers, and
drafts. As the features are created, they are applied directly to the work piece.

•Sketched-based features are based on a 2D sketch. Generally, the sketch is transformed into

a 3D solid by pad , shaft , rib , multi sections.

•Dress-up features are features that are created directly on the solid model. Fillets and

chamfers are examples of this type of feature

Parametric

The dimensions and relations used to create a feature are stored in the model. This enables you to capture
design intent, and to easily make changes to the model through these parameters.

•Driving dimensions are the dimensions used when creating a feature. They include the dimensions
associated with the sketch geometry, as well as those associated with the feature itself. Consider, for
example, a cylindrical pad. The diameter of the pad is controlled by the diameter of the sketched circle, and
the height of the pad is controlled by the depth to which the circle is extruded.

•Relations include information such as parallelism, tangency, and concentricity. This type of

information is typically communicated on drawings using feature control symbols. By capturing this
information in the sketch, CREO enables you to fully capture your design intent up front.
 6.INTRODUCTION TO SHOCK ABSORBER

A shock absorber or damper is a mechanical device designed to smooth out or damp shock
impulse, and dissipate kinetic energy. Pneumatic and hydraulic shock absorbers commonly
take the form of a cylinder with a sliding piston inside. The cylinder is filled with a fluid
(such as hydraulic fluid) or air. This fluid-filled piston/cylinder combination is a dashpot.
The shock absorbers duty is to absorb or dissipate energy. These are an important part of
automobile suspensions, aircraft landing gear, and the supports for many industrial
machines. Large shock absorbers have also been used in structural engineering to reduce the
susceptibility of structures to earthquake damage and resonance.

7.1 DIFFERENT PARSTS OF A SHOCK ABSORBER

7.1.1 Calculation
Material: Steel (modulus of rigidity) (G) = 41000 N/mm2

Mean diameter of a coil (D) = 62mm

Diameter of wire (d) = 8mm

Total no of coils (n1) = 18 Height (h) = 220mm

Outer diameter of spring coil (D0) = D +d =70mm

No of active turns (n) = 14

Weight of bike (w) = 125kgs Let weight of 1 person = 75Kgs Weight of 2 persons = 75×2=150Kgs Weight
of bike + persons = 275Kgs

Rear suspension = 65%

65% of 275 = 165Kgs

Considering dynamic loads it will be double (W) = 330Kgs = 3234N

For single shock absorber weight = (w/2) = 1617N = (W)

Spring index© = 7.75 = 8

Solid length (Ls) = n1×d =18×8 = 144 mm

Free length of spring (Lf)

(Lf) = solid length + maximum compression + clearance between adjustable coils (Lf) = 144 + 282.698 +
0.15 × 282.698 (Lf) = 469.102

Spring rate (K) = 5.719 Pitch of coil,

Stresses in helical springs (P) = 26

Maximum shear stress induced in the wire (τ) = 499.519 N/mm2

Values of buckling factor (KB) = 0.05 (for hinged and spring) The buckling factor for the hinged end and
built-in end springs (Wcr) = 5.719×0.05×469.102=134.139N

7.1.2 Cad modal

1 . Design of base: Draw a circle of diameter 90mm and thickness 1.5mm. Draw a circle on same plane
of diameter 20mm and thickness 500mm.
2 Design of top rod: Draw a circle of diameter 48mm and thickness 510mm. Draw a circle on same
plane of diameter 52mm and thickness 380mm from the bottom of the base .
3 Design of spring: Make a spring of D=37.262
d=8

lf=469

n=14
4. Design of nut: Make a nut of outer diameter 104mm and inner diameter 48mm
5.ASSEMBLY
7.2. STEPS IN FINITE ELEMENT ANALYSIS:
STEP 1: First the domain is represented as finite elements. This is called descritization of domain. Mesh
generation programs called processors, help in dividing the structure.

STEP 2: Formulate the properties of each element in stress analysis. It means determining the nodal loads
associated with all element deformation stress that is allowed.

STEP 3: Assemble elements to obtain the finite element model of the structure.

STEP 4: Apply the known loads, nodal forces in stress analysis. In stress analysis the support of the structure
has to be specified.

STEP 5: Solve simultaneous line algebraic equations to determine nodal displacements in the stress analysis.

STEP 6: Postprocessors help the user to sort the output and display in the graphical output form. A typical
finite element model is comprised of nodes, degrees of freedom, elements material properties, externally
applied loads and analysis type. The finite element method is a numerical analysis technique for obtaining
approximate solutions to a wide range of engineering problems.
 8.FUNCTIONS OF SHOCK ABSORBER

The main function of the shock absorber is to absorb the shocks and damp them as soon as possible so that a
smooth ride can be obtained.

Some other important functions of shock absorber are

1. It limits vehicle body movement.

2. It stabilizes our ride as discussed above.
3. It stabilizes vehicle tires which are disturbed due to sudden shock, hence it is very important for
safety purpose also.
4. It also minimizes tire and body wear of the automobile and hence reduces overall maintenance cost.

It may sound a simple job but this is the main thing on which the comfort level of your ride depends.
 9.CONCLUSION

The suspension system provides the vehicle acts as a safety member by providing the desired height and the

cushioning against the bumps or irregularities present on the road surface.The suspension system absorbs the

energy generate due to road irregularities or bumps, pits etc., and these energy are transferred from the
vehicle

to the earth or road.

 10.Reference
I. Machine design by R.S.KURMI
PSG, 2008.”DESIGN DATA,” kalaikathir achachgam publishers, COIMBATORE, INDIA
II. Automobile Engineering by R.B.Gupta
III. Automotive Maintenance and Trouble Shooting by Ernest Venk,& Edward D. Spicer
IV. En.wikipedia.org/coil springs.
V. En.wikipedia.org/history of helical spring

11.Roles
Kalpak Kamble: PPT Design and Report

Mithun yadav: Part and Assembly modelling in creo

Vivek Shah : Analysis and report

Vivek Kumar:Analysis