Shock Absorber

NOVATEUR PUBLICATIONS
International Journal of Research Publications in Engineering and Technology [IJRPET]

ISSN: 2454-7875
VOLUME 3, ISSUE 3, March-2017
DESIGN OF SHOCK ABSORBER TEST RIG USING MECHANICAL EXCITER
TO DETERMINE TRANSMISSIBILITY AND NATURAL FREQUENCY
AKASH S NANDURDIKAR
Student, Mechanical Engineering, JSPM NTC, Narhe, Pune akashsn53@gmail.com
ANURAJ R NAIK
Student, Mechanical Engineering, JSPM NTC, Narhe, Pune
S. S. PACHPORE
Assistant Professor, Mechanical Engineering, JSPM NTC, Narhe, Pune
PADMANABH A MANURKAR
Student, Mechanical Engineering, JSPM NTC, Narhe, Pune.
VIVEK S NALAWADE
Student, Mechanical Engineering, JSPM NTC, Narhe, Pune
ABSTRACT: become an integral part of the vehicle system. There have

Shock absorber is a very key element in an been many companies since then producing shock
automobile system, which is also an example of under absorbers for different vehicles. Since the production took
damped vibration system. The aim of a Shock absorber place the quality checks also were commenced and many
is to absorb maximum shocks and vibrations in terms types of test has been carried out to check the effectiveness
of kinetic energy and sometimes in terms of potential of a shock absorber using destructive testing or non-
energy as well. Mechanical vibration exciters are destructive testing methods. Transmissibility has always
necessary for modal testing of large components like, been a very important dynamic characteristic of a shock
chassis, Shock absorbers. In this research, a shock absorber. In simple terms, transmissibility can be defined
absorber test rig using mechanical exciter has been as the effectiveness of a shock absorber to absorb the
developed for shock absorber testing and modal shock absorber or any device which isolates the vibrations
testing of Go-kart chassis. A Scotch-yoke mechanism is from the body.
used for design of mechanical exciter. FEA software is Attempts have been made by [1] Nikhil kothawade
used for static and modal analysis of exciter for and others to measure and analyzer the transmissibility of
determining natural frequency and FFT analyzer to a shock absorber for which a shock absorber test rig is
determine the transmissibility of shock absorber. Also designed and developed. [2] research on damping
to validate the results obtained from FFT analyzer FEA characteristics of a shock absorber of heavy vehicles by
software is used. Natural frequency of exciter is mainly Yongjie Lu and others have tested a shock absorber for
depends on its mass and stiffness properties. The damping characteristics and found that a typical shock
results of natural frequency and mode shapes are absorber shows non-linearity, hysteresis. [3] H.R.
obtained from FEA software. The results obtained from Sapramer in his paper Test Rig Design for Measurement of
the FFT analyzer will in the form of a waveform which Shock Absorber Characteristics has stated various dynamic
is used to find out the transmissibility at various loads characteristics of a shock absorber and their effect on
and speeds. The natural frequency of mechanical damping properties.
exciter is obtained from FEA software. Further, the FEA Thus from the above literature, it can be observed
and experimental results of Transmissibility and that testing of a shock absorber is very crucial and that
natural frequency of mechanical exciter are compared measuring the damping characteristics is the need of the
for necessary corrections in design parameters of the hour. This paper mainly focuses on the design and
shock absorber behavior and chassis. development of a Shock absorber test rig to determine its
KEYWORDS: Mechanical Exciter, Transmissibility, effectiveness and natural frequency. Natural frequency of a
Scotch-Yoke mechanism, FEA, FFT analyzer. body is the frequency of vibrating body which will
continue to vibrate at certain frequency even after removal
1. INTRODUCTION: of external force. With the help of natural frequency, the
Shock absorber are used in every vehicle running behavior of a body can be determined. The transmissibility
in this world and since 1912 of its first discovery, it has can be measured in two ways
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ISSN: 2454-7875
a) FFT analyzer 6) Guide-way bush with frame.
b) FEA software 4.2 MOUNTING AND UPPER FRAME:
FFT analyzer will give the graphs and FEA software will be It consists of two mountings bolted across the upper
used to validate the results obtained by FFT. frame and the upper frame is mounted on the guide-way
frame using nut and bolt to ensure flexibility in design.
2. PROBLEM STATEMENT: With the help of bolt assembly, it is possible to test
Design and development of computerized shock different shock absorber of varying stroke lengths.
absorber test rig for a shock absorber with stiffness and The base mounting is a bush with slot and
stroke length to determine transmissibility using FFT arrangement for nut and bolt to trap the lower end firmly.
analyzer and FEA software as well as preparation of The upper end is trapped in the step shaft firmly to
following graphs: ensure there is no deflection along X-axis direction
a) Speed vs Transmissibility 4.3 ELECTRONIC COMPONENTS:
b) Load vs transmissibility Load cell is used to measure the damping force
c) Speed vs time exerted on the shock absorber for complete deformation.
d) Load vs time Accelerometer is used to measure the acceleration of the
e) Displacement vs time moving or vibrating body.
f) Velocity vs time FFT analyzer is a device which uses digital signal
g) Acceleration vs time processing techniques to give in-depth wave form analysis.
FEA process is an analysis process in which the infinite no
3. OBJECTIVES: of elements are converted into finite no of elements and
 To design and develop a shock absorber test rig. analyze the stresses and strains and deformation.
 To design and develop a mechanical exciter.
 To design and manufacture suitable mechanism for
exciter.
 To select bearing for shaft.
 To select coupling.
 To select prime mover for the whole system.
4. EXPERIMENTAL SETUP:
The shock absorber test rig works with the help of
mechanical exciter. The mechanical exciter consists of a
scotch yoke mechanism. The scotch yoke mechanism Figure 4: Block Diagram of Experimental Set-up
consist of three main components namely,
a) Crank. 5. DESIGN OF COMPONENTS:
b) Slotter. 5.1. CRANK
c) Connecting rod. We have selected
The crank is connected to prime mover. When the 40C8 mild steel,
prime mover is set in working mode, the shafted connected Having
with the crank rotates, in return the crank also rotate. Syt = 250 MPA
When the crank rotates, the pin in contact with the slot in Sut = 400 MPA
slotter also moves into the slot and in turn generates the T = 965.6 N-mm
oscillatory motion of the connecting rod. To get the F = 9.42 N
constrained oscillatory motion only in Y- direction, a guide L = 20 mm
way is proposed to reduce the deviation nearly up to zero. B = 15 mm
The Shock absorber test rig is divided into three main H = 64 mm
sections: Based on the above data,
4.1 MECHANICAL EXCITER. σallowable = 125 MPA
Consist of following core component Area = 1008.42 mm2
1) Electric motor. σdesign = F/A
2) Flexible coupling. = 9.42/1008.42
3) Journal bearing. = 9.34x10-3 N/mm2 … Ans
4) Shaft.
5) Scotch yoke mechanism.
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ISSN: 2454-7875
D= 50 mm
H= 50 mm
The sides are faced to obtain the flat surface so
that the nut and bolt gets clamped easily and tightly.
The lower end of the bush is gven a tap of 10 mm
which will get clamped on the threaded connecting rod.
Figure 5.1: Crank with Crank Pin

5.2. SLOTTER AND CONNECTING ROD:
For Slotter,
Material selected is 40C8,
Having
Syt = 250 MPA Figure 5.3: Lower End Mounting Bush
Sut = 400 MPA 5.4 UPPER END MOUNTING:
σb(Max) = 8.4373 N/mm2 The upper end mounting is a stepped shaft with
T = 568.3 N-mm following dimensions:
F = 9.42 N L = 30 mm
Mb = F*r D1 =30 mm (bigger end)
=282.6 N-mm D2 = 15 mm (smaller end)
I =6.03x103 mm4 The purpose is to clamp and eliminate the deflection in
σb = Mb* Y / I x & y direction. A hollow shaft with 15 mm thickness is and
=0.468 N/mm2 … Ans O.D of 30 mm is used to balance the stepped portion.
Figure 5.4: Upper End Mounting Stepped Shaft

5.5 THE SET-UP ASSEMBLY:
The figure shows the set-up assembly, in which all the
deigned components are seen with their respective places.
Figure 5.2: Slotter with Connecting rod

For connecting rod,
H = 150 mm
D = 10 mm
The connecting rod is provieded with threads for a
length of 30 mm from the top so that the mounting bush
can be adapted on the threads and the design will not be
compicated.
5.3 LOWER END MOUNTING: Figure 5.5: Set-up assembly

The lower end mounting is designed based on the
dimensions of shock absorber. The shoch absorber haivng 6. ANALYSIS OF COMPONENTS:
lower end dimensions as 25x15x35 mm And to lock the 6.1 CRANK
shock absorber bolt of dimensions M12 is used. The figures shown below are the static structural
The dimensions are assumed based on the above data and analysis of the crank and pin. The input shaft from motor is
they are:
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ISSN: 2454-7875
connected to the lower end of the crank which will cause it Thus from the above results it can be interpreted that
to rotate. Thus the torque acting at this end is 965.3 N-mm. the mechanism can take a load up to 15 kg with motor
power of 1 HP and 2800 rpm. To increase the capacity of
loading one needs to replace the motor with high capacity
and modify dimensions accordingly.
8. CONCLUSION:
Thus the above paper shows the cad models,
analysis of the designed parts which constitute for the
Figure 6.1: Static Structural analysis of crank development of a mechanical exciter. The present set-up is
6.2 SLOTTER WITH CONNECTING ROD: actually a scale down model of the Shock absorber test rig.
The slotter is connected by crank pin which So if the dimensions are scaled up, then it can be used for
accommodate in the slot of the slotter. So the force acts on heavy duty applications as well. Also it can be used to test
the inside face of the slot and hence the deformation takes springs of various stiffness and shock absorbers of varying
place on the inside face. stroke length. Dimmer is recommended for smooth
The force acting on the inside face is 9.42 N in –z operation of a shock absorber test rig.
direction. Thus stress and strains are shown in the
analysis. REFERENCES:
1) Nitinkumar Anekar1, V.V. Ruiwale2, Shrikant
Nimbalkar3, Pramod Rao4 “Design and Testing Of
Unbalanced Mass Mechanical Vibration Exciter” Ijret:
International Journal of Research in Engineering and
Technology Eissn: 2319-1163 | Pissn: 2321-7308
2) Prashant Mulik1 E. N. Aitavade“Mathematical
Modeling and Experimental Validation of Modification
of Mono-Tube Shock Absorber” Ijsrd - International
Journal for Scientific Research & Development| Vol. 4,
Issue 04, 2016
3) H. R. Sapramer Dr. G. D. Acharya “Test Rig Design for
Measurement of Shock Absorber Characteristics”
(2015).
4) Nikhil S. Kothawade, Amol D. Halwar, Ajay I.
Chaudhari, Bhushan R. Mahajan “Design Of Shock
Figure 6.2: Static Structural analysis of slotter with Absorber Test Rig For Measurement And Analysis Of
connecting rod. Transmissibility”(2014).
7. RESULTS AND DISCUSSION: 5) L.M. Jugulkar, Shankar Singh& S. M. Sawant “Design
It is seen that from the above design and analysis, we are in and Development of Shock Absorber Test Rig” (2013).
position to validate the analytical and FEA results and on 6) Shaohua Li, Yongjie Lu and Liyang Li “Dynamical Test
comparing both we can see whether designed components and Modeling For Hydraulic Shock Absorber on Heavy
are safe or not. Vehicle under Harmonic and Random Loadings” (2012).
Table 6.1: Results 7) Yongjie Lu, Shaohua Li And Na Chen “Research on
Compone Analytical FEA % Remark damping characteristics of shock absorber”.
nt difference 8) M. S. M. Sani, M.M. Rahman, M.M.Noor, K. Kadirgama
Crank 9.63x 10-3 2.91 99. 66 Recommended
with pin N/mm2 N/mm2 And M. R. M. Rejab “Study On Dynamic Characteristics
Slotter 0.468 1.522 69. 25 Recommended Of Automotive Shock Absorber System” (2008).
and N/mm2 N/mm2
connectin
g rod
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NOVATEUR PUBLICATIONS

International Journal of Research Publications in Engineering and Technology [IJRPET]

ABSTRACT: become an integral part of the vehicle system. There have

Figure 5.1: Crank with Crank Pin

Figure 5.4: Upper End Mounting Stepped Shaft

Figure 5.2: Slotter with Connecting rod

5.3 LOWER END MOUNTING: Figure 5.5: Set-up assembly

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