Optimization of 3D Printed Two-wheeler Suspension System

Abstract

The suspension is the very important criteria of a two-wheeler in order to improve the comfort for the operator or rider of the two-wheeler. In most of the two-wheeler’s shock absorbers are used as a suspension system to smooth out or damp shock impulse and dissipate energy by use of spring’s compression and relaxation property. The system consists of a spring which allows the frame and vehicle intact while riding so, suspension and tires to follow the road surface. This paper deals with the studies of the existing shock absorber model and is modified to a new design considering the various parameters like the number of coils and wire diameter of the spring to get the optimized deflection and Von misses stress. The Material of the spring considered in the present design is ASTM A227. For optimizing the design, Autodesk Inventor 2017 inbuilt NASTRON in CAD 2017 is used. From the Finite Element Analysis, it is noted that 13 numbers of coils and 6.7 mm wire diameter has the optimal deflection and stress for the helical coil spring. For this paper, fused filament fabrication technique (FFFT) is used for the prototype development PLA is used. PLA and ABS materials are tested for the load that it can withstand to give the desired deflection and it is suggested at various relevant applications. The models in 3D printable materials are also analyzed for how much load it can withstand.

Keywords: suspension, FEA, additive manufacturing, shock absorber