An automotive spring is a crucial component of a vehicle's suspension system, designed to
enhance driving stability and ride comfort. Known also as coil springs, these components serve
dual purposes:
Improving driving stability by maintaining consistent contact with the road surface.
Absorbing road surface impacts to enhance ride comfort.
The spring rate, or hardness, is adjusted based on the vehicle's intended use, with
corresponding adjustments to the shock absorber for optimal performance.
If you are looking for more details, kindly visit Hengguang.
Automotive springs
play a vital role in shock absorption and stability enhancement. The
suspension design involves fine-tuning the spring's softness and the damping force of shock
absorbers to match the vehicle's usage and operating environment.
While softer springs increase ride comfort by adapting more flexibly to road surfaces, they may
reduce stability by increasing body roll during turns. Conversely, stiffer springs reduce body roll
and enhance stability at the expense of ride comfort. Thus, the spring settings are often
customized to balance between comfort and stability based on the vehicle's purpose.
Auto springs are a crucial component of a vehicle's suspension system, and there are several
types, each with its own unique characteristics and applications. Springs are mechanical
components of immense importance used in effecting motion, improving shock-absorbing
capabilities, etc., in many products. Let's start with something about spring. A spring stores
energy when force is applied and releases it once the force is removed. Typically, regardless of
the type, a spring returns to its original shape upon load removal.
Springs are versatile mechanical devices that store and release mechanical energy, making
them essential components in various industries and applications. From simple coil springs to
complex torsion springs, each type serves a specific purpose.
Springs play a vital role in numerous industries and applications, providing mechanical support,
control, and energy storage. Understanding the different types of springs and their applications
is essential for engineers, designers, and anyone working with mechanical systems. Whether
it's the compression springs in your car's suspension, the leaf springs supporting heavy loads,
or the gas springs providing smooth motion, each type of spring serves a specific purpose,
contributing to the efficiency and functionality of countless products and systems.
Automotive springs
absorb shocks through contraction and expansion, mitigating impacts from
the road. Special metals are used in their construction to endure repeated shocks without
breaking or losing their shape. This functionality extends beyond suspensions to engine parts
and clutches due to their durable and flexible nature.
The suspension system includes:
Shock Absorber (Damper): Dampens the coil spring's motion to stabilize the vehicle
body, enhancing stability and ride quality.
Suspension Arm: Supports the tires and limits their position relative to the road
surface, contributing to driving stability.
Suspension systems are categorized into axle suspension and independent suspension:
Axle Suspension System: Connects the left and right wheels with an axle, offering
simplicity, durability, and ease of maintenance but at the cost of ride comfort.
Commonly used in economically priced vehicles.
Independent Suspension System: Allows independent movement of each wheel,
improving stability and comfort. Preferred in sports and luxury vehicles, though also
found in the front suspension of lower-priced models due to higher production costs.
1. Coil Springs: These are the most common type, found in most passenger vehicles.
They're ideal for:
' Supporting heavy loads
' Providing a smooth ride
' Maintaining vehicle height
2. Leaf Springs: Typically used in:
' Heavy-duty trucks and buses
' Older vehicles
' Vehicles with solid axles
3. Torsion Springs: Used in:
' Suspension systems with torsion bars (e.g., some BMW models)
' Providing stability and support
4. Air Springs: Used in:
' Luxury vehicles (e.g., air suspension systems)
' Heavy-duty trucks (e.g., air-ride suspension)
' Providing a smooth ride and adjustable height
5. Hydraulic Springs: Used in:
' Some heavy-duty applications (e.g., hydraulic suspension systems)
' Providing support and stability
6. Progressive Springs: Used in:
' High-performance vehicles
' Providing a sporty ride and handling
7. Linear Springs: Used in:
' Some passenger vehicles
' Providing a balanced ride and handling
A leaf spring is a type of suspension spring, typically made of several layers or 'leaves' of spring
steel bound together in a specific pattern. These leaves are progressively shorter in length and
are stacked on top of one another, forming a curved or 'arched' shape resembling a bow. This
design provides flexibility and resilience to the spring.
Leaf springs, with their simple yet effective design, have been an integral part of vehicle
suspension systems for centuries. Their ability to distribute weight, absorb shocks, and
maintain stability make them a cornerstone of safe and comfortable transportation.
Understanding how leaf springs function provides valuable insight into the engineering behind
a smooth and secure ride, underscoring their importance in the automotive industry.
Leaf springs are made of rectangular metal plates, known as flat springs or leaves, which are
usually fastened together and are most commonly found in large vehicles, ranging from bigger
cars to trucks and train carts. Different types of leaf springs which are listed below:
1. Semi-Elliptical Leaf Springs
2. Elliptical Leaf Springs
3. Quarter Elliptical Leaf Springs
4. .Three-Quarter Elliptical Springs
5. Transverse Leaf Springs
The construction of a leaf spring comprises several components, each contributing to its overall
Functionality:
The operation of a leaf spring is based on the principles of elasticity and resilience of the spring steel. When a vehicle encounters bumps, potholes, or uneven terrain, the leaf spring flexes
and compresses, absorbing the shocks and vibrations.
Load Distribution: The main leaf, being the longest and thickest, bears the primary load. As the load increases, the helper leaves engage, distributing the weight across the entire length of the Spring.
Flexibility: The arch-shaped design of the leaf spring allows it to flex easily when subjected to
stress or pressure. This flexibility helps maintain a smoother ride even on rough surfaces.
Energy Absorption: As the vehicle encounters bumps or irregularities in the road, the leaf
spring compresses and absorbs the energy generated by the sudden movement. Differences
in spring deflection enable the accumulation of potential energy, which is stored as strain
energy and later released in a more controlled and gradual manner, resulting in a more
comfortable ride for the occupants.
Stability and Traction: Leaf springs play a crucial role in maintaining tire grip on the road. The
consistent pressure and weight distribution facilitated by the leaf spring ensure that the tires
remain firmly planted, enhancing stability during acceleration, braking, and turning.
A leaf spring can either be attached directly to the frame at both eyes or attached directly at
one end, usually the front, with the other end attached through a shackle: a short swinging
arm. The shackle takes up the tendency of the leaf spring to elongate when compressed and
thus makes the suspension softer.
AKAR is one of the leading manufacturer & exporter of automotive, suspension components &
assemblies in India. AKAR has a huge setup in Aurangabad, Maharashtra, India. AKAR delivers
the finest and strongest suspension for commercial vehicles which makes it the best in the
industry. All the products and designs we create are custom-made, to fit the requirements and
specifications of each order we receive.
AKAR was incorporated in the year . We are a top-notch manufacturer of Parabolic Leaf
Springs, Multi-Leaf Springs, Mechanical Trailer Suspension Assemblies, Trailer Leaf Springs, Ubolts, and Leaf Spring Bushes for almost all kinds of Trucks & Trailers. Our goods are well
suited for the Heaviest of Vehicles & the Toughest of Terrains. Our product is in high demand both in
domestic as well as in the international market. For the last three decades, we have maintained
the international standard of our product quality and continuously strive to exceed the client's
expectations. We are regularly catering to the requirements of our customers in worldwide.
AKAR strive hard to make sure all our process is up to date with the current market trends.
The wide product range is suitable for all sorts of vehicles, from the lightest utility vehicles to
the heaviest trucks, built for long-haul or off-road missions.
After the rolling and forging operations, the spring leaves are quenched and tempered to
achieve the required mechanical properties. They are then shot-peened to increase the
fatigue life. Magnetic particle inspection tests are carried out when required, Using a specific
Process,
AKAR can manufacture high stress springs. The high performances obtained enable a weight
reduction and, as a result, allow the vehicle payload to be increased. All the major truck
manufacturers have now opted for this technological solution.
Multi Leaf springs, as the name suggests, has multiple leaves. The leaves have constant width
and each leaf has constant thickness.
Over the years, the combination of great passion, long man hours, computerized techniques
and a team of professionals from design, research and manufacturing department, have
helped Mack Springs usher a foundation of strong relationships with automobile sectors
across the world.
We manufacture products for automobile companies in USA, Europe, Africa, Middle East and
Asia. We take immense pride for our consistency in providing impeccable products an
exemplary service to our customers.
Akar manufactures various types of Multi Leaf, Conventional spring, and conventional
assemblies. These leaf springs are widely used for Heavy Duty trucks Special Application
Vehicles SUVs & MUVs, LCV & HCVS in Trucks and Buses.
Akar manufactures various types of Multi Leaf Conventional Spring Assemblies with helper.
Akar manufacturs both types of helper assemblies; conventional & parabolic. These leaf
springs are widely used for Heavy Duty trucks Special Application Vehicles SUVs & MUVs, LCV
& HCVS in Trucks and Buses.
Akar manufactures various types of Multi Leaf Bogie type parabolic assemblies. These leaf
springs are widely used for Heavy Duty trucks Special Application Vehicles SUVs & MUVs, LCV
& HCVS in Trucks and Buses.
Akar manufactures various types of Multi Leaf Spring assemblies for trailer. These leaf springs are widely used for Heavy Duty trucks Special Application Vehicles SUVs & MUVs, LCV & HCVS in Trucks and Buses.
Parabolic Springs have constant width with full length leaves, and each leaf is of variable
thickness. No machine can roll an ideal parabolic profile.
Parabolic Springs has less interleaf friction, better fatigue life, better resilience, better quality ride and high value to weight ratio.
Akar
is Equipped with an imported parabolic machine with manufacturing capability from
6mm to 60 mm thickness rolling capacity with minimum Parabolic thickness tolerance. Various
type of leaf springs are manufactured and supplied Worldwide.
Akar
is Equipped with an imported parabolic machine with manufacturing capability from
6mm to 60 mm thickness rolling capacity with minimum Parabolic thickness tolerance. Various
type of leaf springs are manufactured and supplied Worldwide.
Full Taper Springs are usually used on heavy duty trucks and trailers. Full Taper Springs
typically have anywhere between 1 to 4 leaves that differ in thickness, but the length of the leaves is approximately the same. The main purpose of full Taper Spring is to act as a cushion between the axle and chassis, to protect the vehicle and cargo.
The major design goals of full Taper Springs are it reduces spring stiffness; reduce inter-leaf friction and reducing spring weight.
By tapering each leaf in the full Taper Spring the load or stress is spread out evenly along theentire length of the leaf. In fact, each leaf acts as a separate spring.
We mainly manufacture products for major domestic truck manufacturers. As well as
manufacturing according to the needs of our customers, such as to achieve the weight
reduction of trucks and buses, improve riding comfort, and meet the particular needs of
different regions, we also manufacture special leaf springs. We are also working to improve
our production efficiency with industrial robots and aim to provide leaf springs of high quality at low prices.
A suspension is essentially a damped spring producing opposing force when being compressed. Springs sustain the weight of the vehicle. Dampers oppose the spring movement, dissipating their energy and preventing them to bounce without control.
Contact us to discuss your requirements of automotive suspension springs. Our experienced sales team can help you identify the options that best suit your needs.
The force produced by the springs depends on the distance they are compressed and it's given by Hooke's Law:
where
is the spring's stiffness or spring rate in , and
is the contact depth or compresion distance in .
The force produced by the dampers depend on how fast the suspension is being compressed or elongated (contact speed), opposing the movement.
When a wheel is lifted from the ground the suspension produces no force. At the slightest contact possible it also won't produce any force. As the spring gets more compressed, more force is produced proportionally to the contact depth:
The compression limit is the suspension distance. Beyond this point the spring has reached its maximum force and cannot compress further. A hard contact with the rigid body is produced.
The slope of the force line is given by the stiffness . The more stiffness, more steep slope.
The suspension position is the contact depth where the spring force matches exactly the force applied on the spring. In vehicles this force is typically caused by the weight supported by the wheel:
The suspension force is calculated as:
When the suspension is not moving the contact speed is 0. This happens when the vehicle is either resting, cruising at constant speed or under constant acceleration. The suspension position for a specific wheel may then be calculated as:
where is the actual weight being supported by that wheel.
The suspension properties may be studied from the point of view of the oscillating behavior (Harmonic oscillator). The associated concepts are used to study the reactions of the suspension in different situations.
Understanding vehicle suspension as harmonic oscillator
A suspension behaves as harmonic oscillator under certain conditions, and may be studied as a harmonic oscillator under those conditions. Read Application to real vehicles below.
While a suspension based on specifying the oscillating properties (frequency, damping) is possible, simulating a suspension as a generic harmonic oscillator is generally a bad idea and may easily provide incoherent results. It's not just one, but four (or more) attached suspensions with complex interactions among them: weight shifting, cargo, aerodynamic downforce, road conditions...
Given the force produced by the suspension at a specific steady state (contact speed = 0) the effective sprung mass value for studying that situation may be calculated as:
When the vehicle is at rest, cruising at constant speed or under constant acceleration on a flat surface the sum of the sprung masses of all the wheels matches the mass of the vehicle exactly.
Using the sprung mass you may calculate the natural frequency for the spring under those conditions. The natural frequency is the rate at which the spring can respond to changes in load:
The natural frequency defines the oscillating behavior of the suspension. For example, a typical family car is set up to exhibit a natural frequency somewhere between 5 and 10.
The effective sprung mass may also be used for studying the damping behavior, that is, the rate at which the suspension dissipates the energy stored at the spring. We may calculate the damping ratio for learning whether the suspension will be under-damped, over-damped or critically-damped:
A damping ratio greater than 1.0 means over-damping (sluggish suspension), a value of exactly 1.0 is critically-damped, and a value less than 1.0 is under-damped (bouncy suspension). Values for realistic vehicles are in the range of 0.2 and 0.6. The damper rate that targets a specific damping ratio may be calculated by rearranging the equation above:
In under-damped suspensions ( ) the frequency at which the system oscillates is different than the natural frequency:
Another interesting concept for the simulation is the number of simulating updates that will occur during each spring oscillation. This number is given by the alpha ratio:
Applying the Nyquist theorem we deduct that a physically correct simulation should have alpha >= 2. Smaller values means that the simulation sampling rate is not enough to simulate the given spring rate.
Suspensions in real vehicles don't have constant frequency and damping ratio at all times. You may calculate and study the oscillating behavior in specific situations separately: at rest, accelerating, braking... Weight transfer on some of these situations actually affects the behavior of the suspension. That's the challenge of configuring suspensions in real vehicles: finding a good balance for most situations.
If the vehicle is under constant acceleration (accelerating / braking / cornering) the weight is redistributed among the wheels. Wheels will be supporting more or less load than in their positions at rest. This effectively modifies the oscillating properties of the suspensions at those specific situations, therefore producing different reactions. For instance, imagine a racing car heavily braking at the end of a long straight before entering a slow curve. If that part of the track is a bumpy surface then the suspension must be set up properly for ensuring correct handling while braking over the bumps. Another example is the downforce caused by aerodynamic surfaces. Suspension will have different behavior on high speeds due to the additional load. Studying the oscillating behavior of the suspension in this detail is critical for setting up racing cars that react properly on every situation.
We may summarize the role of the vehicle suspension as:
When the suspension is not moving the dampers have no effect. This happens when the vehicle is at rest, cruising at constant speed, or under constant acceleration. Otherwise, weight transfers occur among the suspensions. The springs should be strong enough for sustaining the weight of the vehicle preventing the suspension to reach its limits on all situations, including weight transfers.
When the formulas for the Harmonic Oscillator (above) are applied to vehicles in those situations they yield a surprising result:
So the single factor that defines the frequency of our suspension is the contact depth. The frequency of the suspension will vary on the different situations (accelerating, braking, cornering...) according to the contact depth. Note that this contact depth includes any pre-load of the spring inside the suspension strut.
As a result, configuring the vehicle suspension for a similar behavior in a broad range of conditions requires minimizing the changes in the contact depth in those conditions. There are several strategies for this:
Vehicle Physics Pro includes a variety of suspension components allowing different ways of configuring the suspension:
If you are looking for more details, kindly visit bmw x3 rear coil springs.