Industrial_Studies

Existing Design [pic] It’ a combination of coil spring and shock absorber system on a wheel. It has become an independent design, and any road shocks vibrations are absorbed by the chasis, instead of channelling it through to the driver. This meant that, it uses fewer parts than the conventional dampening system, which in turn reduces the weight of the car and fewer elements that could wear out. The Macpherson strut system itself is a load bearing system, this is because the spring and the shock absorber is opposing each other, where the weight of the car pushes the shock absorber down and the spring coil resist and counters in the other direction; this is what holds the car in place. | |Components |Materials |Manufacturing | |1. |Casing Tube |ERW tube |Turning | |2. |Storage Tube |ERW tube |Turning | |3. |Working Cylinder |CRW tube |Turning | |4. |Piston Rod |ENB bright |Turning | | | |bar | | |5. |Valves |Spring steel |Stamping | |6. |Piston |Cast aluminium |Rolling | |7 |Coil Spring |Low alloy,medium |CNC Machining | | | |carbon steel | | |8 |Washers |Stainless Steel |Powder Sintering | |10 |Nuts/Bolts |Steel |CNC Machining | |11 |Front Upper Shock Mount |Steel |Casting | |12 |Bracket |Steel |CNC Machining | |13 |Lower Mount |Mild Steel |CNC Machining | Parts,Materials and Manufacturing Processes Manufacturing Casing tube – The casing tube is basically made of ERW tube. The casing tube holds the working cylinder and the storage tube. The machines use is Turn-o-mat, engraving machine and welding machine. Working cylinder – This is where the piston, piston rod and the valve is located. It goes through proses such as parting, chamfering, and calibration, drilling and deburring. Machines use to manufacture this component is the Turn-o-mat, hydraulic press, and drilling machines. Storage Tube – The storage tube is where the fluid is being held. The machines such as Turn-o-mat, engraving machine and welding machine are used to manufacture this part. Piston Rod – The purpose of the piston rod is to transfer the upward and downward thrust from the rod to the piston. The piston rod is being connected to the upper mount of the shock absorber. The material use for the piston rod is high carbon steel. Manufacturing process involve is turning, parting, drilling, and. Machine to process the piston rod is the drilling machine, grinding machine, and thread rolling machine. Valves – The valve generates resistance to forces created by the up and down motion. Material use for this component is spring steel. It is send for annealing and punching process to manufacture the valve. Piston- is attached to the end of the piston rod and works against the oil to control spring and suspension movement. The piston is made of cast aluminium. The process involved in its manufacturing are lapping and machining. The main machine is the lapping machine. [pic] Piston Coil Spring- an apparatus which when an external force is applied changes its shapes and when the external force is removed it returns to its original shape. This in turn supports the weight of the car with the help of the shock absorber. Manufacturing a spring has a wide variety of method; one of the methods is cold winding using a CNC machine. Wire is pushed over a support block to a ridged head which deflects the wire and forcing it to bend. It is then coated by painting it, with zinc or chromium. [pic] Spring Coil Nuts and Bolts- which are commonly known as fasteners, helps tighten or loosen any mechanical assembly, machineries and to hold different parts together. It is machined using CNC machine by forcing through a die, and then one side is stamped to make the head of the bolt. It is then heat treated to seal the finishing. [pic][pic] Nuts and Bolts Front Upper Shock Mount(Upper Cap)- located on top of the shock absorber, it is to hold the spring coil in place. It is manufactured by sand casting because it can withstand the displacement of the spring and the forces of the spring. Surface finishing will be needed to reach the final product. [pic] Upper Cap Bracket- utilizes as a joint between the shock absorber and the car manoeuvring system. It is manufactured using a CNC machining because of its intricate part. It is then welded to the lower shaft of the shock absorber to complete the system. [pic] Bracket Lower Mount(Lower Cap)- located under the spring shock absorber, which its main function is to hold the spring in place from the bottom. This is manufactured using steel because to withstand the displacement and the force of the spring coil; CNC machining is used to produce the precise dimensions of a lower cap [pic] Washers - a tiny round plating with a hole in the middle used as a spacer which is usually inserted between a screw or a nut. Its main function is to distribute the load of a screwing fastener, when met with the nut and bolt to secure the upper mount of the shock absorber. CNC machine punched small round rings on stainless steel sheet; is then sand grinded for surface furnishing. Assembly |Assembly Method |Description |Components | |Press on fitting |It is type of fit for mating parts. It is used when the parts do not have to move relative to each |Coil spring, | | |other. The spring is compressed before being put on the absorber. Press fitting is low cost and |piston rod | | |simple method for assembling parts or | | | |components.(http://www.ticona.com/home_page/tech/design/press_fits.htm) | | |Seam Welding |Seam welding is a continuous process using electrode wheels on generally overlapping work |Casing tube, | | |pieces.(http://www.esab.com/gb/en/education/processes-seam-welding.cfm). The bracket is being weld |bracket, cap and | | |to the bottom part of the absorber. The casing tube is being welded to the cap. |lower mount. | |Bolted Connections|Bolt is used to connect base plateto the front upper shock mount. Washers are placed between the |Bolts and washers | | |bolt and the base plate to distribute the load caused by threaded fasteners and sometimes act as | | | |spacer. | |