Material Selection and Constraints for Suspension Coil
Kartik 2021AM10804
Anany 2021AM10792
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Introduction
A suspension coil is very important in absorbing shocks and maintaining the stability
of the vehicle under different load conditions. There exists a huge variety of load conditions, ranging from static vehicle weight to dynamic forces experienced on rough terrains.
Keeping this in consideration, material selection must be done cautiously to ensure performance, safety, and endurance.
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Material Selection
2.1
High-Tensile Spring Steel
Mechanical Properties:
• Ensures the coil can withstand high loads with a factor of safety of 1.5.
• The S-N curve performance supports a high number of load cycles as required by
the cycle fatigue loads observed.
Manufacturing:
• Proper heat treatment and forming processes yield consistent mechanical properties.
• Easily available and economically feasible for mass production.
Corrosion Resistance:
• Surface treatments such as coatings or galvanization enhance durability in harsh
automotive environments.
2.2
Composite Materials
This serves as an exploratory option but is useful.
Potential Advantages:
• Lightweight nature may help reduce the overall suspension mass, contributing to
improved fuel efficiency.
Limitations:
• Composites are not yet extensively validated for high-cycle fatigue applications
compared to spring steel.
• Manufacturing challenges exist, as processing composites for uniform properties
under cyclic loading remains less mature.
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Constraints and Justification
• Fatigue Life: A material with high fatigue endurance is crucial given the millions
of cycles experienced in service. High-tensile spring steel is best suited due to its
proven fatigue resistance.
• Environmental Exposure: The material must perform well under moisture, salts,
and chemicals. Spring steel, when treated properly, provides excellent resistance.
• Strength-to-Weight Ratio: High-tensile spring steel offers a balanced compromise. While composites are lighter, they may not meet rigorous fatigue demands.
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Conclusion
High-tensile spring steel is the preferred material for suspension coils due to its excellent
mechanical properties, consistent manufacturing qualities, and proven durability under
cyclic loads. While composite materials offer a promising avenue for future weight reduction, their current fatigue performance validation remains limited. Thus, high-tensile
spring steel is justified as the ideal choice to ensure reliability and longevity in automotive
suspension systems.
AI was used only to generate the LaTeX code to enhance the report’s formatting and
presentation.
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