Design and Evaluate A Model of Vehicle Suspension System by Using Fem

The suspension system assists the vehicle's braking system in terms of safety, driving pleasure and passenger comfort when driving without road noise, bumps or vibrations. If the roads were perfectly smooth, a vehicle suspension system would not be necessary. As a result, the wheel of the machine undergoes a sudden vertical movement as it moves over the bumps. To improve the stability of the suspension system design multiple spring in vehicle suspension system and the design multiple spring in vehicle suspension system for different materials to enhance the results. Final conclusion of the analysis the Titanium Ti-6Al-4V is the much batter material than other two materials Cast iron and titanium Ti-13V-11Cr-3Al.  Because the yield stress of Titanium Ti-6Al-4V is higher the titanium Ti-13V-11Cr-3Al. And the density of the Titanium Ti-6Al-4V was lower than cast iron and titanium Ti-13V-11Cr-3Al.


I. INTRODUCTION
The suspension system assists the vehicle's braking system in terms of safety, driving pleasure and passenger comfort when driving without road noise, bumps or vibrations. If the roads were perfectly smooth, a vehicle suspension system would not be necessary. It is these irregularities that disturb the wheels. Bumps and holes in the road raise and lower the wheel of a vehicle perpendicular to the road surface. The strength of force depends on whether the wheel encounters a weak or significant inequality. the wheel of the machine undergoes a sudden vertical movement as it moves over the bumps. Learn more about suspension design for light and low power vehicles that resist fatigue during operation. The suspension system includes the spring and the fluid damping system. The spring absorbs the energy of an applied force. This energy is stored in the spring until the force is released, so that the spring returns to its original size, shape and position. It is therefore important that the vehicle suspension keeps the wheel in contact with the road surface.

1) Vehicle Engine and Suspension
In a typical motor vehicle, the main competition lies between the manufacturing processes of the powertrain components and the suspension system. Typical forged components used in vehicles include the crankshaft, connecting rod, and camshaft and suspension components, such as the control arm, steering joint and wheel hub. For a better understanding of the vehicle components, we will briefly discuss here the technical characteristics of the engine and chassis components, in particular the steering joint.

II. LITERATURE REVIEW
M. M. Patunkar et al. [1] This article shows that leaf springs area unit one in every of the oldest suspension components that they still use frequently, especially in commercial vehicles. The literature review shows that leaf springs area unit designed as generalized force components, within which the position, speed and orientation of the axis bearings offer the reaction forces within the frame mounting positions. Another half should be targeted, as the automotive industry is increasingly interested in replacement the steel spring with a composite spring due to its high strength to weight ratio.

B. Pyttel et al. [2]
this text presents long-term fatigue tests on compressed helical compression springs, that were created using a special springloaded 40 Hz fatigue tester. The test springs were composed of 3 totally different materials: hardened spring valve steel oil and steel for valve springs in SiCrV alloy and stainless-steel. With a selected test strategy in a very test cycle, up to 500 springs with a wire diameter of d = 3.0 millimeter or 900 springs with d = 1.6 metric linear unit were tested at completely different stress levels simultaneously. VOLUME 5, ISSUE 10, OCTOBER 2019 www.ijoscience.com 8 Yunan Prawoto et al. [3] This article describes the helical springs of the vehicle, their distribution of basic stresses, the properties of the fabric, the producing and therefore the common defects. a detailed discussion of the parameters that influence the quality of the volute springs is also presented. The coil springs are not excluded, that corresponds to the tendency of the automotive industry to constantly reduce weight. A consequence of the load reduction effort is that the need to use elastic device materials with considerably greater efforts decades a gone than similar styles. The use of a superior steel strength has each benefits and disadvantages.
Ladislav Kosec et al. [4] during this document, the failure analysis of a spring of a vehicle of a rear shock absorber is examined and analyzed. Since the protecting layer on the surface of the spring is damaged, corrosion has occurred. the mix of corrosion and fatigue has resulted within the failure of a helical spring for cars.

III. OBJECTIVE
• To investigate the vehicle suspension system by improving finite element analysis (FEA) • To analysis and compare von misses stresses and factor of safety by the previous material.
• To improve the stability of the suspension system design multiple spring in vehicle suspension system • To analysis the design multiple spring in vehicle suspension system for different materials to enhance the results.

1) FEA Analysis on Vehicle Suspension System.
In this project, we use the CAD software and ANSYS version 18.2 analysis. Here we can create a CAD model and determine the stress value and the deformation value in ANSYS. 18.2 To study different constraints and deformations, these were imported into the ANSYS network software and gave different results. The mesh model is essentially made up of nodes and elements. Tetra elements offer a better result than other types of elastic elements. Therefore, the elements used in this analysis are gloomy elements. The calculated forces and boundary conditions were applied to the mesh model in ANSYS 18.2. The design parameters obtained from the analysis of the finite elements above were compared for the materials and the best was selected.

Preparation of model
A CAD model is prepared in CATIA.

2) Steps of Working
Step 1: Collecting information and data related to VSS.
Step 2: A fully parametric model of the VSS for both cases are created in CATIA V5R20 Step 3: Model obtained in Step 2 is analyzed using ANSYS 18.2.
Step 4: Finally, we compare the results obtained from ANSYS.

3) Finite elements analysis
Finite element analysis is a branch of fluid mechanics that uses numerical analysis and data structures to solve and analyze problems involving fixed structures. The ANSYS 18.2 software was used for this work.

ANSYS functions:
Finite element analysis uses the ANSYS software that engineers can use to perform the following tasks: • To create prototypes and computer components, transfer the CAD models of structures into a system product.
• Improves the profile of structural elements through the optimization of the shape.
• It is possible to study physical reactions such as voltage levels, temperature distributions or electromagnetic fields.
• To reduce production costs, design optimization occurs at the beginning of the development process. www.ijoscience.com 9 • Test prototypes in environments where this would otherwise be undesirable or impossible (eg biomedical applications).

4) Steps of ANSYS Analysis
The different analysis steps involved in ANSYS are mentioned below.

Preprocessor
The model setup is basically done in preprocessor. The different steps in pre-processing are  Build the model  Define materials  Generation of element mesh

Building The Model
 Creating a solid model within Catia.  Importing model created in a computer-aided design (CAD) system.

6) Results OF 1 ST Case
The analysis of Cast iron at different load condition.

11) Results OF 3 rd Case
Adding spring in this case, and the analysis is to be done on the consideration of double spring in cast iron at different loading conditions. 2) Cast iron result in case 1, 2, and 3.

Equivalent stress:-
Graph 2 Maximum von miss stress of the cast iron material.

3) Titanium result in case 1, 2, and 3.
Graph 3 Maximum von miss stress of the Titanium materials.

V. CONCLUSION
The analysis of the duration and static stresses of a VSS using finite element analysis techniques has provided a reliable design that can be used in VSS projects. This work presents a fatigue index for the SSV and based on the simulation obtained, we can say that:  The current VSS made of a carbon alloy can be reduced to a lighter VSS with good durability and good workability with the advantage of low CO2 emissions.
 The FOS for carbon alloys with an adequate elasticity point lower than the VMS value is about 0.50 for the different loads considered.
 Titanium Ti-6Al-4VSolution Treated has an FOS of approximately 2.38 in 3 rd case. The total strength of the Titanium is increase due to double spring. The value of equilavant stress decrease in case 3 rd .and total factor of safety increases up to 2.38 in third case.
 The value of maximum von mises stress decrease in case third and the value of FOS increases. The value of Factor of safety in case third maximum 2.38 and minimum 1.76.
 But in Case of cast iron the value of FOS 0.63 at 14kN/m3 radial force. And 0.46 at 22kN/m2.
 The total weight of Aluminum 7075-T6 is lower than the other material. And factor of safety of the aluminum in case third is 1.29.the factor of safety of Aluminum 7075-T6 is greater than one .so the aluminum have ability to stand at higher load.
 Final conclusion of the analysis the Titanium Ti-6Al-4V is the much batter material than other two materials Cast iron and titanium Ti-13V-11Cr-3Al. Because the yield stress of Titanium Ti-6Al-4V is higher the titanium Ti-13V-11Cr-3Al. And the density of the Titanium Ti-6Al-4V was lower than cast iron and titanium Ti-13V-11Cr-3Al.