AS GLOBAL CLASSES

CHAPTER- Suspension systems

What is a suspension system?
The chassis of vehicle is connected to the front and rear wheels through the medium of springs, shock
absorbers and axles. All parts perform the function of protecting parts from shocks are known as
suspension system.
The automobile chassis is indirectly connected with axles by springs. It is done to prevent the vehicle body
from road shocks due to bounce, pitch, roll or sway. These road shocks provide an uncomfortable ride and
also additional stress to the automobile frame and body.
Suspension system has a spring and damper. The energy of road shock produced by the spring oscillates.
These oscillations are arrested by the damper known as shock absorber.
The front and rear suspensions of a car may be designed differently. The suspension system of our car is in
charge of smoothing out the ride and keeping the vehicle in control. To offer steering stability and good
handling, the suspension system increases the friction between the tires and the road.
Components of Suspension System
1. Springs are used to neutralize the shocks from the road surface.
2. Dampers, called shock absorbers, are used to improve a riding comfort by limiting the free oscillation of
springs.
3. Stabilizer, called sway bar or anti-roll bar, is to prevent lateral swinging of the car.
4. A linkage system holds above components to control the longitudinal and lateral movements of wheels.
Functions or Objectives of Suspension System
1. To eliminate road shocks from transmission to vehicle components.
2. To obtain good road holding while driving, cornering and braking.
3. To keep the proper steering geometry.
4. To obtain a particular height to body structure.
5. To resist the torque and braking reactions.
8. To maintain the stability of the vehicle while traveling over rough round or when turning in order to
minimize the rolling, pitching or vertical movement tendency.
9. To safeguard the occupants against road shocks and provide a riding comfort.
10. To minimize the effects of stresses due to road shocks on the mechanism of the motor vehicle and
provide a cushioning effect.
Requirements of Suspension System
1. There should be minimum deflection.
2. It should be of minimum weight.
3. It should have low maintenance and low operating cost.
4. It should have minimum tyre wear.
5. It should be of low initial cost.
Principles of Suspension System
The principles of the suspension system are due to springing action of motor vehicles-
1. Supporting the weight of vehicle.
2. Absorbing satisfactorily larger and smaller road impacts with the help of a single springing device.
3. The reduction of rolling or pitching of the body to a minimum design and attachment of springs.

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Spring & Unsprung mass:
The total mass of the vehicle, for the purpose of the suspension design is broken up into two parts spring &
unsprung. Unsprung weight consists of tyres , wheels & suspension components that attach these items to
the main body - chasis structure . The rest of the vehicle is sprung weight. In dynamic terms , all items that
move with the wheel are unsprung. This also include portion of the shock absorber & sway bar which are
attached to the suspension. The portion that are attached to the frame & body are sprung. Light
components can be kept in contact with the ground more easily than heavier ones. Motion of the wheels &
related assembly must be stopped before the spring can return the tyre to the surface. Therefore, the
lighter the component, the less momentum there is to control. With greater unsprung weight, the
suspension has to allows the use of softer spring, which make for a smoother ride.
Low unsprung mass thus allow the use of softer springs, which move for a smoother ride. With less
unsprung weight, more weight can be controlled with spring & shock absorber, thus giving a better ride
quality. Resonance due to the sprung & unsprung weight adversly affect ride, handling & steering. The
higher the unsprung weight, the higher the hop & tramp amplitudes & the lower the ride quality, road
holding & stability.
Types of Suspension System
(i) Front end suspension
(a) Independent front suspension
(b) Rigid axle front suspension
(ii) Rear end suspension
(a) Longitudinal leaf spring rear suspension
(b) Transverse leaf spring rear suspension
(c) Coil spring rear end suspension.
Independent Front Suspension
The independent front suspension was developed in the 1930’s to improve vehicle ride control and riding
comfort. In this type of suspension, each front wheel is mounted on its own axle and independently
supported by a coil or torsion bar or leaf spring. This allows the wheels to respond individually to road
conditions. Now-a-days, all vehicles use this suspension system. Coil springs are commonly used in this
suspension system. This suspension system completely prevents the wheel wobble. A greater wheel
movement is utilized without affecting the steering system. The steering conditions and qualities are
improved by a wider spacing of the front springs.
Rigid Axle Front Suspension
Rigid axle front suspension is also called as dependent front suspension. This type of suspension uses a
solid axle. This type of suspension has been universally used before drawing the independent front wheel
suspension. This design consists of one steel or aluminium beam extending the width of the vehicle. This
beam is held in place by leaf springs. This design also uses kingpins and bushings to attach the wheels
outboard of the axle. Because of its load carrying ability, the solid axle is only used on heavy trucks, and
off-road vehicles. It is not suitable for use on modern passenger cars for three important reasons.
Types of independent front suspensions:
1. Longitudinal suspension
2. Transverse suspension
3. Sliding suspension
4. Mac Pherson Strut and link type suspension
5. Parallelogram type suspension or Wishbone type
6. Trailing link type suspension
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7. Vertical guide suspension.
Compare rigid axle Suspension and independent suspension
Rigid axle Suspension Independent suspension
The spring is attached to rigid beam axle There is no rigid axle beam
Wheels move vertically having reaction on the Each wheel move vertically without any reaction on
other wheel other wheel
Used for heavy vehicle like trucks Used for light vehicle like car at front
More tyre scrub, reduces tyre life Less tyre scrub and increases tyre life
Steering geometry change Steering geometry does not change
Provide slightly rigid suspension due to higher Provide softer suspension due to low spring rate
spring rate

McPherson Strut

• MacPherson struts are a specific type of independent suspension found on a car's front axle. It replaces
the steering rod and performs the functions of suspension and vibration dampening at the same time.
• The system comprises a wishbone or a significant compression link balanced by a secondary link that
serves as the bottom mounting point for the wheel's hub or axle. This lower arm design places the
wheel both laterally and longitudinally.
• The MacPherson Strut features a simple construction that consists of a damper and a coil spring. The
spring is first added to the system so that it can absorb shock energy caused by a sudden jerk on the
road.
• Then, the shock absorber uses hydraulic fluid to release the heat this shock energy creates.
• Any unintended movements of the vehicle caused by problems with the road are effectively restrained
when both of these setups function together in this suspension system.

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Wishbone type suspension

• The wishbone type is the most popular type of independent suspension system.
• It consists of two wishbone-shaped arms to locate the wheel.
• Each wishbone or arm has two mounting points to the chassis and one joint at the knuckle.
• The shock absorber and coil spring mount to the wishbones to control vertical movement.
• The vehicle weight is transmitted from the body and the cross member to the coil spring through which
it goes to the lower wishbone member.
• The wishbones not only position the wheels and transmit the vehicle load but also rest acceleration,
braking and cornering forces.
• The upper arms are shorter in length then the lower ones. This helps to keep the wheel track constant
thereby avoiding the tyre scrub thus minimizing wear.
• The wishbone arms are like the chicken wishbone or letter V in shape, so the system is called as
wishbone type suspension system.
• The upper arms are shorter in length than the lower ones. This helps to keep the wheel track constant
thereby avoiding the tyre scrub thus minimizes the tyre wear.
Leaf Spring:
Leaf springs are multi-layered steel plates clamped together. Leaf springs are formed by bending. They are
made of long strips of steel. Each strip is named as Leaf. The long leaf is called master leaf / main leaf, and
it consists of eyes at its both ends.

One end is fixed to the chassis frame, the other end is fixed to the shackle spring. The spring will get
elongated during expansion and shortened during compression.
This change in length of spring is compensated by the shackle. The U-bolt and clamps are located at the
intermediate position of the spring. The bronze or rubber bushes are provided on both eyes on the master
leaf.

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Helper Leaf Springs:

The helper springs are used in heavy vehicles for rear suspension. They allow for a wide range of loading.
When vehicle fully loaded the main spring as well as helper spring to come in action and absorb the road
shocks. When the load of the vehicle is less the helper spring will not act and the main spring only absorb
the road shocks.

Coil springs:
Coil spring is made of thick steel wires a length of special spring steel, usually round in section which is
wound in the shape of coil. The ends of coil spring are kept flat so that could seat properly. They can store
twice energy per unit volume in comparison to leaf spring. To seat the coil springs pan shaped brackets or
spring seats are attached to the axles. This suspension is also used in combination with torque tube or
torque rod.

Torsion bar / Torque rod:

Torsion bars are long steel rods of either circular or square cross section. The springing action is generated
by the torsional forces when the torsion bar is twisted.
A torsion bar suspension, also known as a torsion spring suspension, is any vehicle suspension that uses a
torsion bar as its main weight-bearing spring.
The effective spring rate of the bar is determined by its length, cross section, shape, material, and
manufacturing process.
Torsion bar spring is lighter as compared to leaf springs and also it occupies less space.
There are two main disadvantages of the torsion suspension. The first is that it does not take the braking or
driving trust so that additional linkages have to provided for that purpose. Secondly, the absence of friction
force and hence of damping which is a necessity to control the vibrations produces due to road shocks.

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What is a shock absorber?

A shock absorber is a mechanical or hydraulic device designed to absorb and damp shock impulses. This is
achieved by converting the kinetic energy of the shock into another form of energy (typically heat) which is
then dissipated. A rubber shock absorber is the most common type, due to its durable high elasticity, and
ability to eliminate vibration, shock, and sound insulation. It has a required shape and satisfies the
requirements of stiffness and strength.
The rubber vibration absorber has certain damping functions such as the ability to absorb mechanical
energy, especially high-frequency oscillation energy. The lost energy can be saved and used later in
electromagnetic shock absorbers, among other forms of shock absorbers. Shock absorbers often enable
vehicles on uneven roads to be softened.
Functions of shock absorbers
• The primary function of a shock absorber is to absorb or dampen the compression and rebound of the
springs and suspension.
• It helps to control unwanted and excess spring motion
• It keeps tires in contact with the road at all times
• The shock absorber ensures the safest control and quicker braking response of your car.
Telescopic Shock Absorber:
The shock absorber is a part of suspension system used as springing device to compromise between
flexibility and stiffness. It absorbs the energy of shock converted into the vertical movement of the axle by
providing damping and dissipating the same into heat.
Construction of Telescopic Shock Absorber:
The upper eye of the telescopic shock absorber is attached to the axle and the lower eye is attached to the
chassis frame as shown in Figure 4.55. A two-way valve V1 is connected to a rod. Another one two-way
valve V2 is connected to the lower end of the cylinder. The fluid occupies in the space between above and
below the valve VI and also the annular space between the cylinder and tube. A gland is provided on the
head. Fluid scrapped out by the rod is brought down into the annular space through the inclined passage.

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Working of Telescopic Shock Absorber:
When the vehicle comes across a bump, the lower eye will move up. So, the fluid follows from the lower
side of the valve V1 to the upper side. Due to less volume of the space above valve V1 than the volume of
the rod, the pressure is exerted on valve V2 Thus, the damping force is produced by this pressure of the
fluid. The fluid will flow from the upper side of the valve V1 to the lower side when the lower eye moves
down and from the lower side of the valve V2 to its upper side.
When a car absorbs shocks from the road surface, the suspension springs will compress and expand
because the spring has the characteristic of continuing to oscillate for a long time of oscillation to stop. So,
a riding comfort will be poor even the damp oscillation is supplied. Shock absorbers provide better road-
holding characteristics and improved steering stability to tires.
Gas-filled mono-tube shocks Absorber:
To prevent foaming and bubbles in the oil, which degrades shock-absorber performance, a gas-filled mono-
tube shock has a chamber of high-pressure nitrogen above the oil chamber. This high-pressure gas makes it
difficult for bubbles to form in the oil, even when the shock absorber moves in and out very quickly, as it
might while traveling rapidly on a very rough or washboard road.
Gas-filled shocks are expensive since they require strict manufacturing tolerances, but they are very
resistant to fade and consequently are popular in off-road racing and rallying. Gas-filled shocks, by the way,
are not the same as “air shocks,” which use an air chamber separate from the shock oil. An air shock is
actually an air spring that raises or lowers the vehicle when air is added or removed through a valve.

Advantages of telescopic shock absorber:

1. A large amount of energy is dissipated due to a large volume of fluid displaced without causing a high-
temperature rise.
2. There is no wear development in the damper with the absence of connecting arm pivots.
3. The applied force is increased when compared to the indirect-acting type. Low fluid pressure due to the
fairly large piston area occurs with reduced levers.
4. The leakage is very less due to lower pressure and absence of the rotating shaft entering the reservoir.
Advantages of Gas-filled shock absorber
1. The full diameter of the tube can be used as a working chamber and thereby a larger volume of oil
becomes available for damping.
2. The larger volume of oil made available in any one stroke because of the adjustments between gas and
oil volumes provides a better facility for the damping force.
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3. The tolerance to heat in the gas-filled shock absorber is greater.
4. Gas-filled shock absorber gives longer life to tires and other related components in the suspension such
as springs, brushes, etc.
Difference between the telescopic shock absorber and gas -filled shock
absorber.
Sr.No. Telescopic shock absorber Gas filled shock absorber
1. In this only hydraulic oil is used. In this, both oil and gas are used.
2. The tolerance to heat is less. The tolerance to heat in gas-filled shock the
absorber is greater.
3. In this foaming of oil may occur. A gas-filled shock absorber is designed to reduce
the foaming of the oil.
4. Atmospheric conditions do not The atmospheric condition affects on the system.
affect the system.
5. The operating cost is lower. The cost of nitrogen gas is more as compared to
hydraulic oil.
6. Maintenance is comparatively easy. Maintenance is difficult as compared to the
hydraulic shock absorber.
7. The damping effect is relatively less. Better damping is obtained.

Stabilizer or Anti-roll bar

When one road wheel is deflected more than the other, then there is a tendency for the vehicle to roll. To
obviate a stabilizer is used in the form of a torsion bar. The torsion bar C is fixed to springs A and B by
means of two short rods D. The torsion bar is supported in two bearings E which are fixed to the frame or
the car floor pan.
The working of the stabilizer bar consider a situation when the car rolls out such that the nearer side
moves up. That decreases load on one spring A which causes the nearer rod D to move down. On the other
hand the load on another spring B is increased, thereby letting the farther rod D to move up.
Thus the C which is supported in bearings undergoes twisting. It is the resistance of the bar to twisting that
counters the tendency of the cat to roll out, thereby providing stability against lateral forces. A stabilizer as
used on a front axle with independent suspension.

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Troubleshooting Suspension
A vehicle’s suspension system is a component of springs, tyres, tyre air, anti-sway/roll bars, shock
absorbers, struts, bushings, bearings, ball joints, linkages, steering system, and spindles that connects a
vehicle to its wheels and allows motion. This is one of the most used components of a vehicle which can
eventually wear out. A bad suspension results to difficulty in controlling the vehicle, preventing a smooth
ride. With this, a suspension repair will be necessary.
1. Pulling to One Side When Driving & Turning
Drifting or pulling to one side while driving and turning is one of the most common signs of suspension
problems. This may be due to an uneven tire wear, poor alignment, broken spring, or the shocks can no
longer provide stability to the body against the centrifugal force during a turn.
2. Rough Rides
If we start to notice every bump in the road, or we feel your vehicle bounces while driving, it’s an indicator
that our vehicle’s shock absorbers or struts are worn out and need replacement.
3. One Corner is Visibly Lower than the others
A damaged spring (shocks) is usually the culprit why one corner of our vehicle sits lower than the rest while
on a level ground.
4. Dipping or Nose-Diving When Stopping
When stepping on the brakes causes our vehicle to lurch forward or downward further than normal, this
could mean that our shocks or struts are worn out and need immediate replacement.
5. Oily Shocks or Fluid Leaking
Take a look underneath our vehicle to check your shocks or struts. If they appear to be oily or greasy,
there’s a chance that they are leaking fluid and are not working properly. Also, when we notice that your
vehicle is leaving a trail of fluid when driving, this may be another symptom that our shocks are damaged
and need replacement.
6. Difficulty in Steering
Another warning sign that something is wrong with our suspension is when we notice difficulty when
steering, especially when our driving slowly. This may be caused by low power steering fluid, loose steering
belt, faulty power steering pump, or worn control arm bushings.
7. Uneven Tyre Treads
When our vehicle’s tyre treads are wearing out unevenly, it could be an indicator that the suspension
doesn’t have the capability to hold the car evenly. It is a sign that our suspension may be putting uneven
pressure on the tyres, creating balding spots on the tread while other spots are kept intact.
8. Noticeable Bouncing
Feeling some bumps in the road as we drive is normal, and usually, we should notice the bouncing to
stabilize almost immediately after we encounter the bumps. However, if we continue to notice the
bouncing even after hitting a bump or pothole, our vehicle may have worn shocks or a damaged leaf
spring.

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