Design development and analysis of cylindrical spring with variable pitch for two wheelers

Technological advancements are growing at a rapid rate for comforting mankind. Every sector including manufacturing, aerospace, and automobile are growing in terms of technical enhancements, material development and design innovations. An attempt has been made in this investigation to design the spring system used in the suspension system. A suspension system or 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 travelling over the rough ground, leading to improved ride quality, and increase in comfort due to substantially reduced amplitude of disturbances. Hence, the design of spring in suspension system forms the vital designing component. Here, a spring is designed for which material consideration formed the basis of analysis owing to the impact loads the spring experiences during the working cycle. The spring design combines two basic designs i.e. variable pitch and cylindrical designs to amalgamate the advantages and eliminate the drawbacks of individual designs. A 3D model was generated using SolidWorks software which was further imported in another software i.e. ANSYS to analyze various mechanical parameters. A material study was carried out in terms of mechanical properties for the selection of spring material. The selected material were alloy steel (vanadium chrome spring steel) and high carbon steel (music wire spring steel) which is commonly used. The analysis was carried out by varying the applied load on the spring and it was recorded in term of stress and deformation. It can be inferred that the results of analysis showed spring was designed successfully and fulfilled the motives of two basic spring designs in a single combined spring structure. The result was also in accordance to the previous research which showed alloy steel as a promising material for the springs in the suspension system of the vehicle.