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A Seminar report on
CERTIFICATE
This is to certify that Harsh Krishnan Srivastava has worked under our supervision and guidance for the senior titled Nitro Shock Absorber in partial fulfillment of the requirements for the award of degree of BACHELOR OF TECHNOLOGY in Mechanical Engineering of UTTAR PRADESH TECHNICAL UNIVERSITY, LUCKNOW during academic year 2010-2011. It is further seen that to the best of our knowledge .This work has not be submitted to any university in fulfillment of requirement of any degree and has not be published elsewhere .His submission of the above mentioned course is here by approved.
ACKNOWLEDGEMENT
The writing of the acknowledgement after completion of report is pleasure for me. It signals the completion of text, but more important if provides an opportunity to express my indepthness of those to contribute on so much to me and to this report. I feel honoured to express my heart fold and sincere gratitude to Mr.RiteshDixit, Kanpur Institute of Technology for his constant and generous help and able guidence throughout .I wish to convey my deep sense of gratitude to my teachers for their able guidance throughout the study. I would also like to thank my valuable friends for their excellent cooperation during this period. With great pride, I would like to thank my correspondents as without their help bringing out this seminar project would have been impossible.
PREFACE
It is required to take a seminar project report for the partial fulfillment of the B.Tech programme so as to practical experience now in the mechanism world each company tries to launch new technologies in the market. Their main aim is to develop our system which is efficiency and also eco-friendly and is accepted at large by focusing on various attitudes like price, quantity and other special unique features.
CONTENTS
INTRODUCTION NEED FOR SHOCK ABSORBERS
Page No.
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SHOCK ABSORBER ACTION GAS FILED SHOCK ABSORBERS TYPES WORKING ADVANTAGES MOUNTING TIPS CONCLUSION REFERENCES
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SYNOPSIS
In the present scenario of automobile industry manufacturers are trying to produce comfortable and safe vehicles which the consumers are looking for. A shock absorber is a damping element of the vehicle suspension, and its performance directly affects the comfortability, dynamic load of the wheel and dynamic stroke of the suspension. The conventional type of shock absorbers has got the main drawback that it causes foaming of the fluid at high speeds of operation. This results in a decrease of the damping forces and a loss of spring control. The gas filled shock absorbers are designed to reduce foaming of the oil and provide a smooth ride for a long period.
INTRODUCTION
For a smooth and comfortable ride the disturbing forces should be eliminated or reduced considerably by using some devices. Shock absorbers are such devices which isolate the vibrations by absorbing some disturbing energy themselves. Of the many types telescopic shocks are widely used which has got the draw back that the flow of oil in the cylinder can cause foam of oil and air to form. These limit the optimum throughout of the flow in the valves. Gas shocks represent an advance over traditional shocks. Nitrogen filled gas shock absorbers are the results of years of extensive research and development with top flight shock design engineers. They are designed for both lowered and stock vehicles to provide shock absorbers that would out perform anything on the market today. Nitro shock absorbers are high quality, nitrogen filled shocks designed and gas charged specifically for each vehicle application. The addition of nitrogen under pressure limits the foaming effect and increases efficiency.
A BRIEF HISTORY
In the early 1900's, cars still rode on carriage springs. After all, early drivers had bigger things to worry about than the quality of their ride - like keeping their cars rolling over the rocks and ruts that often passed for roads. Pioneering vehicle manufacturers were faced early on with the challenges of enhancing driver control and passenger comfort. These early suspension designs found the front wheels attached to the axle using steering spindles and kingpins. This allowed the wheels to pivot while the axle remained stationary. Additionally, the up and down oscillation of the leaf spring was damped by device called a shock absorber.
These first shock absorbers were simply two arms connected by a bolt with a friction disk between them. Resistance was adjusted by tightening or loosening the bolt. As might be expected, the shocks were not very durable, and the performance left much to be desired. Over the years, shock absorbers have evolved into more sophisticated designs.
WHAT SHOCKS DO
Let's start our discussion of shock absorbers with one of very important point: despite what many people think, conventional shock absorbers do not support vehicle weight. Instead, the primary purpose of the shock absorber is to control spring and suspension movement. This is accomplished by turning the kinetic energy of suspension movement into thermal energy, or heat energy, to be dissipated through the hydraulic fluid. Shock absorbers are basically oil pumps. A piston is attached to the end of the piston rod and works against hydraulic fluid in the pressure tube. As the suspension travels up and down, the hydraulic fluid is forced through tiny holes, called orifices, inside the piston. However, these orifices let only a small amount of fluid through the piston. This slows down the piston, which in turn slows down spring and suspension movement. The amount of resistance a shock absorber develops depends on the speed of the suspension and the number and size of the orifices in the piston. All modern shock absorbers are velocity sensitive hydraulic damping devices - meaning the faster the suspension moves, the more resistance the shock absorber provides. Because of this feature, shock absorbers adjust to road conditions. As a result, shock absorbers reduce the rate of: 8
Shock absorbers work on the principle of fluid displacement on both the compression and extension cycle. A typical car or light truck will have more resistance during its extension cycle then its compression cycle. The compression cycle controls the motion of a vehicle's unsprung weight, while extension controls the heavier sprung weight.
Compression cycle
During the compression stroke or downward movement, some fluid flows through the piston from chamber B to chamber A and some through the compression valve into the reserve tube. To control the flow, there are three valving stages each in the piston and in the compression valve. At the piston, oil flows through the oil ports, and at slow piston speeds, the first stage bleeds come into play and restrict the amount of oil flow. This allows a controlled flow of fluid from chamber B to chamber A. At faster piston speeds, the increase in fluid pressure below the piston in chamber B causes the discs to open up away from the valve seat. At high speeds, the limit of the second stage discs phases into the third stage orifice restrictions. Compression control, then, is the force that results from a higher pressure present in chamber B, which acts on the bottom of the piston and the piston rod area. 9
Extension cycle
As the piston and rod move upward toward the top of the pressure tube, the volume of chamber A is reduced and thus is at a higher pressure than chamber B. Because of this higher pressure, fluid flows down through the piston's 3-stage extension valve into chamber B. However, the piston rod volume has been withdrawn from chamber B greatly increasing its volume. Thus the volume of fluid from chamber A is insufficient to fill chamber B. The pressure in the reserve tube is now greater than that in chamber B, forcing the compression intake valve to unseat. Fluid then flows from the reserve tube into chamber B, keeping the pressure tube full. Extension control is a force present as a result of the higher pressure in chamber A, acting on the topside of the piston area.
Mono-Tube
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Bore size is the diameter of the piston and the inside of the pressure tube. Generally, the larger the unit, the higher the potential control levels because of the larger piston displacement and pressure areas. The larger the piston area, the lower the internal operating pressure and temperatures. This provides higher damping capabilities. Ride engineers select valving values for a particular vehicle to achieve optimal ride characteristics of balance and stability under a wide variety of driving conditions. Their selection of valve springs and orifices control fluid flow within the unit, which determines the feel and handling of the vehicle.
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increasing number of vehicles using uni-body construction, shorter wheelbases and increased use of higher tire pressures. The design of twin tube gas charged shock absorbers solves many of today's ride control problems by adding a low pressure charge of nitrogen gas in the reserve tube. The pressure of the nitrogen in the reserve tube varies from 100 to 150 psi, depending on the amount of fluid in the reserve tube. The gas serves several important functions to improve the ride control characteristics of a shock. The prime function of gas charging is to minimize aeration of the hydraulic fluid. The pressure of the nitrogen gas compresses air bubbles in the hydraulic fluid. This prevents the oil and air from mixing and creating foam. Foam affects performance because it can be compressed - fluid can not. With aeration reduced, the shock is able to react faster and more predictably, allowing for quicker response time and helping keep the tire firmly planted on the road surface.
An additional benefit of gas charging is that it creates a mild boost in spring rate to the vehicle. This does not mean that a gas charged shock would raise the vehicle up to correct ride height if the springs were sagging. It does help reduce body roll, sway, brake dive, and acceleration squat. This mild boost in spring rate is also caused by the difference in the surface area above and below the piston. With greater surface area below the piston than above, more pressurized fluid is in contact with this surface. This is why a gas charged shock absorber will extend on its own. The final important function of the gas charge is to allow engineers greater flexibility in valving design. In the past such factors as damping and aeration forced compromises in design.
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PRINCIPLE OF OPERATION
The damping mechanism of a shock absorber is viscous damping. Viscosity is the property of a fluid by virtue of which it offers resistance to the motion of one layer over the adjacent on. The main components of a viscous damper are cylinder, piston and viscous fluid. There is a clearance between the cylinder walls and the piston. More the clearance more will be the velocity of the piston in the viscous fluid and it will offer less value of viscous damping coefficient. The basic system is shown below. The damping force is opposite to the direction of velocity.
The damping resistance depends on the pressure difference on the both sides of the piston in the viscous medium. The figure shown below shows the example of free vibrations with viscous damping.
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( Fx )dt
0
2 /
c(dx/dt
0
* dx/dt)dt =
2 /
c(dx / dt )dt
0
Let us assume the simple harmonic motion of the type x = Asint (dx/dt) = Acost The equation for
E =
2 /
This shows that the energy dissipation per cycle is proportional to the square of the amplitude of motion. The total energy of a vibrating system can be either maximum of its potential or kinetic energy. The maximum kinetic energy of the system can be written as E = (KE) 1/2mxmax = 1/2mA
max
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The inside parts of a shock absorber The upper mounting is attached to a piston rod. The piston rod is attached to a piston and rebound valve assembly. A rebound chamber is located above the piston and a compression chamber below the piston. These chambers are full of hydraulic fluid. A compression intake valve is positioned in the bottom of the cylinder and connected
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hydraulically to a reserve chamber also full of hydraulic fluid. The lower mounting is attached to the cylinder tube in which the piston operates.
During compression, the movement of the shock absorber causes the piston to move downward with respect to the cylinder tube, transferring fluid from the compression chamber to the rebound chamber. This is accomplished by fluid moving through the outer piston hole and unseating the piston intake valve. During rebound, the pressure in the compression chamber falls below that of the reserve chamber. As a result, the compression valve will unseat and allow fluid to flow from the reserve chamber into the compression chamber. At the same time, fluid in the rebound chamber will be transferred into the compression chamber through the inner piston holes and the rebound valve.
Spring
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Separation between oil and nitrogen gas by a free piston provides stable damping force, as well as high performance. Single-tube
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Strut
Double-tube
This type consists of double tubes that comprise part of the support structure of the suspension. Filled with lowpressure nitrogen gas, it provides stable damping force.
Inverted type
Structurally, this is a single-tube type placed upside down. Its large-diameter pipe provides sufficient rigidity to bear the heavy load from the car body, characteristic of a strut.
When connected to the power steering system at a point higher than normal, this type allows the cabin space to be expanded and the maneuvering stability improved.
Type with separately mounted spring (rigid axle, etc.) Unit damper
Because the spring is mounted separately, this type features a simple structure comprised of a damping mechanism
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When the piston rod is moved into the shock absorber, oil is displaced as in double tube principle. This oil displacement causes the dividing piston to press in the gas chamber, thus reducing it in size. With the return of the piston rod the gas pressure returns the dividing piston to its starting position. Whenever the oil column is held at a static pressure of approximately 25 times atmospheric pressure, the pressure decreases behind, the working piston cannot be high enough for the gas to exit from the oil column. Consequently, the gas filled shock absorber operates without foaming.
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Single tube with high pressure Twin-tube with low pressure gas.
The oil seal surrounding the piston rod in the upper body of the shock absorber has been especially designed with one lip to prevent the entry of dust and with a further two sealing lips to prevent oil escaping.The base of the seal is in the form of a circular strip which functions as a non-return valve.The flexibility of the strip allows the oil to flow back into the reserve tubes and keeps the gas pressure solely on the oil in the reserve.
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The low pressure shock absorber design has enabled Monroe to solve certain problems associated with the MacPersonsystem.These shock absobers produce a very comfortable ride and very precise steering.
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WORKING
Bump Stroke: When the piston rod is pushed in oil flows without resistance from below the piston through the orifices and the non-return valve to the enlarged volume above the piston. Simultaneously, a quantity of oil is displaced by the volume of the rod entering the cylinder. This volume of oil is forced to flow through the bottom valve into the reservoir tube (filled with air (1 bar) or nitrogen gas (4-8 bar)). The resistance, encountered by the oil passing through the footvalve, generates the bump damping.
Rebound Stroke:
When the piston rod is pulled out, the oil above the piston is pressurized and forced to flow through the piston. The resistance, encountered by the oil on passing through the piston, generates the rebound damping. Simultaneously, some oil flows back, without 25
resistance, from the reservoir tube through the footvalve to the lower part of the cylinder to compensate for the volume of the piston rod emerging from the cylinder.
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The piston rod passes to the upper end of the pressure tube through rod guide and the seal. The rod guide assist the piston to move freely inside whereas the oil is kept inside by the seal. The movement of the fluid is controlled by the base valve which is located at the bottom of the pressure tube.
The gas helps in minimizing the aeration of the hydraulic fluid. The creation of foam is prevented because the gas compresses air bubbles in the hydraulic fluid. Reduction of aeration enhances the working capacity of the shocks. This shock absorber gives more flexibility to the engineers to design valve. The additional advantage of the shock absorber is that it creates a mild boost in spring rate to the vehicle.
The handling is improved through roll reduction and the reduction of sway and dive. It reduces aeration and give smooth control in different types of road conditions.
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The heat may lead to the reduction of damping capability in the shock absorber however in gas charged shocks this is reduced to a considerable extent.
Advantages
Give fine and smooth ride. It can adapt itself quickly to different road and weight conditions. It has two shocks in itself that is-comfort and control Sensitive Damping (ASD) Twin Tube Shocker
Acceleration
Twin tube ASD shocker brings the benefits of both the comfort and the control. Twin tube ASD design shocker uses the compression valve which provides a bypass to fluid flow around the compression valve. The compression valve is designed in such a way that it senses a bump in the road and adjust the shock automatically to absorb the impact thereby giving greater control to the shock.
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How It Works
In mono tube design, the damping force is created by deflective discs which are heat treated stainless spring steel. The discs are generally stacked in a pyramid pattern. The shim with the largest diameter faces the piston. The disc which is in close proximity to piston open first and allows the flow of the oil. The rate of the shock both on compression and rebound can be changed by increasing thickness and sometimes diameters.
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Monotube shock absorber consists of two chambers which are stacked on each other and are separated by a "floating piston". Both the piston are filled with oil and gas respectively. In the oil filled chamber damping forces are created. The gas chamber is separated by a floating piston. The compression of shock results in the compression of the air chamber by the floating piston which displaces the volume of the shaft. This type of pressure creates the rod-pressure. The pushing of piston rod also forces the floating piston towards downwards thereby increasing pressure in both gas and oil section. This also results in the flow of the oil through the piston. This type of resistance generates the bump damping. Rebound damping is produced when the oil between piston and guide is forced to flow through the piston. This happens when the piston is pulled out
Benefits
Gives good control and smooth ride. Monotube Shocks Can be mounted at any angle. It is lighter as compared to equivalent twin tube designs. Has high severity life. Adjusts to road conditions automatically. 30
Features
The features of the mono tube shock absorber include:
It has distinctive mono disc design. The vehicle can be assembled easily. Weight is light. Element of lag and fade is absent. Reliable and durable.
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Rebound Stroke:
When the piston rod is pulled out, the oil between piston and guide is forced to flow through the piston. The resistance encountered in this manner generates the rebound damping. At the same time, part of the piston rod will emerge from the cylinder and the free (floating) piston will move upwards.
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Better durability :
Single-tube construction also allows for a larger internal working area, reducing stress and fatigue for better durability. De Carbons monodisc valving system features a single moving part that drastically reduces inertia and friction, to improve durability and performance. Better cooling of the mono tube design results in lower operating temperatures and thus longer life.
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CONCLUSION
In the current scenario of automobile industry the need for vehicles which provides smooth and comfort ride is growing. Nitro shock absorbers are designed to be ultimate in performance and comfort. In a country like ours whose roads are not up to world standards the need for automotive components like nitro shocks are necessary. It goes without saying that if the right choice is made the improvements in vehicles ride and handling can be shocking.
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REFERENCES
1. In For A Shock, S.B.L Beohar; Mechanical Systems and Signal Processing. 2. Automotive Encyclopedia; Tobolt, Johnson. 3. Auto Mechanical Fundamentals; Stockel. 4. http://belltech.net 5. http://monroeshocks.com
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