Design and Analysis Approach for Material Optimization of Two-Wheeler Shock Absorber Springs

Shock absorbers play a crucial role in two-wheelers by absorbing shocks from uneven terrains, improving ride comfort, and ensuring stability. This study focuses on the design and analysis of a helical spring used in the rear suspension system of a two-wheeler, aiming to enhance stiffness while minimizing stress and deflection. A comparative analysis is conducted on springs made from Inconel 600, chromium vanadium, and stainless steel to determine the most efficient material. The shock absorber spring is modelled, and finite element analysis is performed using ANSYS to evaluate its mechanical behaviour under various loading conditions, including the weight of the rider and the vehicle. A structural analysis is carried out to assess the spring’s deformation at different vibration modes. Key performance parameters such as von Mises stress, von Mises strain, and total deformation are analysed to determine material suitability. The study reveals that an increase in coil diameter leads to higher stress concentration in the spring. Among the three materials tested, chromium vanadium demonstrates superior performance in terms of strength, stiffness, and durability, making it the most suitable material for shock absorber springs. The results provide valuable insights into material selection for enhancing the efficiency and longevity of two-wheeler suspension systems.