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Systems
Thepurposeofthesuspensionistoprovide
thevehiclewiththefollowing:
1.Asmoothride
2.Accuratesteering
3.Responsivehandling
4.Supporttheweightofavehicle
5.Maintainacceptabletirewear
FRAMECONSTRUCTION
Theframeofavehiclesupportsalltherunning
gearofthevehicle,includingtheengine,
transmission,rearaxleassembly(ifrearwheel
drive),andallsuspensioncomponents.
Therearemanytermsusedtolabelordescribethe
frameofavehicle,includingthefollowing.
LadderFrame
Aladderframeisacommonnameforatypeofperimeterframewherethe
transverse(lateral)connectingmembersarestraightacross.
PerimeterFrame
Aperimeterframeconsistsofweldedor
rivetedframemembersaroundtheentire
perimeterofthebody.
StubTypeFrames
Astubframeisapartialframeoftenusedonunitbodyvehiclestosupportthe
powertrainandsuspensioncomponents.Itisalsocalledacradleonmanyfront
wheeldrivevehicles.
UnitBodyConstruction
Unitbodyconstruction(sometimescalledunibody)isadesignthatcombinesthe
bodywiththestructureoftheframe.Thebodysupportstheengineanddriveline
components,aswellasthesuspensionandsteeringcomponents.
Theareaseparatingtheengine
compartmentfromthepassenger
compartmentiscalledthebulkhead.The
heightandlocationofthisbulkheadpanel
toalargedegreedeterminestheshapeof
therestofthevehicle.
Thetrackofavehicleisthedistancebetweenthe
wheels,asviewedfromthefrontorrear.Awide
trackvehicleisavehiclewithawidewheelstance;
thisincreasesthestabilityofthevehicle,especially
whencornering.
Thewheelbaseofavehicleisthedistancebetween
thecenterofthefrontwheelandthecenterofthe
rearwheel,asviewedfromtheside.
UNSPRUNGWEIGHT
Asuspensionsystemhastobedesignedtoallowthewheels
tomoveupanddownquicklyoverbumpsanddipswithout
affectingtheentireweightofthecarortruck.Thisweight
iscalledunsprungweight.Forbesthandlingandride,the
unsprungweightshouldbekeptaslowaspossible.
Sprungweightisthetermusedtoidentifytheweight
ofthecarortruck,whichdoesnotmoveupanddownand
issupportedorsprungbythesuspension.
TYPESOFSUSPENSIONS
Earlysuspensionsystemsonoldhorsewagons,buggies,andoldervehiclesuseda
solidaxleforfrontandrearwheels.
Mostvehiclestodayuseaseparatecontrolarmtypeofsuspensionforeachfront
wheelwhichallowsformovementofonefrontwheelwithoutaffectingtheother
frontwheel.Thistypeofsuspensioniscalledindependentfrontsuspension.
Springs
Asuspensionspringservestwopurposes.First,it
actsasabufferbetweenthesuspensionandframeto
absorbverticalwheelandsuspensionmovement
withoutpassingitontotheframe.Second,each
springtransferspartofthevehicleweighttothe
suspensioncomponentitrestson,whichtransfersit
tothewheels.
SpringMaterials.Mostspringsare
madeofatemperedsteelalloyknownas
springsteel,usuallychromesiliconor
chromevanadiumalloy.
COILSPRINGS
Coilspringsaremadeofspecialroundspringsteel
wrappedinahelixshape.Thestrengthandhandling
characteristicsofacoilspringdependonthe
following.
1.Coildiameter
2.Numberofcoils
3.Heightofspring
4.Diameterofthesteelcoilthatformsthespring
Thelargerthediameterofthesteel,the
stifferthespring.
Theshortertheheightofthespring,
thestifferthespring.
Thefewerthecoils,thestifferthe
spring.
Springsaredesignedtoprovidedesiredrideandhandlingandcomeinavarietyof
springends.
SpringRate
Springrate,alsocalleddeflectionrate,
isavaluethatreflectshowmuchweight
ittakestocompressaspringacertain
amount.
Aconstantratespringcontinuestocompressatthesameratethroughoutits
completerangeofdeflection.
Avariableratespringmaycompressoneinchundera100poundload,butonly
compressanadditionalhalfaninchundera200poundload.
Beforeaspringisinstalledonavehicleoranyloadisplacedonit,itisatits
uncompressedlength,orfreelength.Onceinstalled,theweightofthecornerof
thevehiclerestingonthespringiscalleditsstaticload.
CoilSpringMounting
Coilspringsareusuallyinstalledinaspringpocketorspringseat.Hardrubber
orplasticcushionsorinsulatorsareusuallymountedbetweenthecoilspringand
thespringseat.
SpringCoatings
Allspringsarepaintedorcoatedwith
epoxytohelppreventbreakage.A
scratch,nickorpitcausedbycorrosion
cancauseastressriserthatcanleadto
springfailure.
Insteadofcuttingspringstoloweravehicle,thereareseveralmethodsavailable
thatarepreferredifthevehiclemustbelowered:
1.replacementsprings
2.replacementspindles
LEAFSPRINGS
Leafspringsareconstructedofoneormorestripsoflong,narrowspringsteel.
Thesemetalstrips,calledleaves,areassembledwithplasticorsyntheticrubber
insulatorsbetweentheleaves,allowingfreedomofmovementduringspring
operation.
Theendsofthespringarerolledorloopedtoformeyes.Rubberbushingsare
installedintheeyesofthespringandactasnoiseandvibrationinsulators.
Theleavesareheldtogetherbyacenterbolt,alsocalledacenteringpin.
Oneendofaleafspringismountedtoahangerwithaboltandrubberbushings
directlyattachedtotheframe.Theotherendoftheleafspringisattachedtothe
framewithmovablemountinghangerscalledshackles.
Reboundorspringalignmentclipshelppreventtheleavesfromseparating
whenevertheleafspringisreboundingfromhittingabumporriseintheroadway.
Singleleafsteelsprings,calledmonoleaf,areusedonsomevehicles.Asingleor
monoleafspringisusuallytaperedtoproduceavariablespringrate.
Toprovideadditionalloadcarryingcapacity,especiallyontrucksandvans,
auxiliaryorhelperleavesarecommonlyused.
CompositeLeafSprings
Fiberglassreinforcedepoxyplasticleaf
springshavebeenusedonproduction
vehicles.Using70%fiberglasswith30%
epoxycomposite.
Leafspringrateincreaseswhenthethickness
increases,anddecreasesasthelength
increases.
Automotive Steering, Suspension, & Alignment, 4/e
By James D Halderman
TORSIONBARS
Atorsionbarisaspringwhichisalong,round,hardenedsteelbarsimilartoa
coilspringexceptforastraightbar.
Oneendisattachedtothelowercontrolarmofafrontsuspensionandtheother
endtotheframe.Whenthewheelshitabump,thebartwistsandthenuntwists.
SUSPENSIONPRINCIPLES
1.Transverse(orsidetoside)wheelsupport.
Transverselinksarealsocalledlaterallinks.
2.Longitudinal(fronttoback)wheelsupport.
Somesuspensiondesignsuseanadditionalmembertocontrolforwardback
movement.
STEERINGKNUCKLES
Asteeringknuckleishardtoclassifyeitheraspartofthesuspensionoraspartof
thewheel.Aknuckleservestwopurposes:
Tojointhesuspensiontothewheel
Toprovidepivotpointsbetweenthesuspensionandwheel
TheonlyknucklethatusesakingpinisasteeringknuckleonanIbeamortwinI
beamfrontsuspension.Thesteeringaxisistheverticalcenterofthekingpin.
CONTROLARMS
Acontrolarmisasuspensionlinkthatconnectsaknuckleorwheelflangetothe
frame.
BALLJOINTS
Balljointsareactuallyballandsocketjoints,similartothejointsinaperson's
shoulder.Balljointsallowthefrontwheelstomoveupanddown,aswellasside
toside(forsteering).
Ifthecoilspringisattachedtothetopoftheuppercontrolarm,thentheupper
balljointiscarryingtheweightofthevehicleandiscalledtheloadcarryingball
joint.Thelowerballjointiscalledthenonloadcarryingorfollowerballjoint.
Ifthecoilspringisattachedtothelowercontrolarm,thenthelowerballjointis
theloadcarryingballjointandtheupperjointisthefollowerballjoint.
BallJointDesign
Therearetwobasicdesignsofball
joints:compressionloadedand
tensionloaded.
Aballjointthatdoesnotsupportthe
weightofthevehicleandactsasa
suspensionpivotisoftencalleda
followerballjointorafrictionball
joint.
STRUTRODS
Somevehiclesareequippedwithroundsteelrodswhichareattachedbetweenthelower
controlarmatoneendandtheframeofthevehiclewithrubberbushings,calledstrutrod
bushings,attheotherend.
Strutrodsarealsocalledtensionor
compressionrodsorsimplyTCrods.
Somevehiclemanufacturerscallthestrut
rodadragrodbecauseitwasattachedin
frontofthewheels,andthereforeacted
onthelowercontrolarmasiftodragthe
wheelsbehindtheirattachmentpoints.
Ifastrutrodhasanutonbothsidesofthebushings,thenthe
strutrodisusedtoadjustcaster.
STABILIZERBARS
Mostcarsandtrucksareequippedwithastabilizerbaronthefrontsuspension,
whichisaround,hardenedsteelbar(usuallySAE4560or4340steel)attachedto
bothlowercontrolarmswithboltsandrubberbushingwasherscalledstabilizer
barbushings.
Astabilizerbarisalsocalledanantiswaybar(swaybar)orantirollbar(roll
bar).Astabilizerbaroperatesbytwistingthebarifonesideofthevehiclemoves
upordowninrelationtotheotherside,suchasduringcornering,hittingbumps,
ordrivingoverunevenroadsurfaces.
Stabilizerlinksconnecttheendsofthestabilizerbartothelowercontrolarm.
SHOCKABSORBERS
Shockabsorbersareusedonallconventionalsuspensionsystemstodampenand
controlthemotionofthevehicle'ssprings.Withoutshockabsorbers(dampers),
thevehiclewouldcontinuetobounceafterhittingbumps.
Themajorpurposeofanyshockorstrutisto
controlrideandhandling.Standardshock
absorbersdonotsupporttheweightofa
vehicle. Thespringssupporttheweightof
thevehicle;theshockabsorberscontrolthe
actionsandreactionsofthesprings.Shock
absorbersarealsocalleddampers.
Asawheelrollsoverabump,thewheelmovestowardthebodyandcompresses
thespring(s)ofthevehicle.Asthespringcompresses,itstoresenergy.Thespring
thenreleasesthisstoredenergy,causingthebodyofthevehicletorise(rebound).
ShockAbsorberOperation
Thehydraulicshockabsorberoperatesontheprincipleoffluidbeingforced
throughasmallopening(orifice).
GasChargedShocks
Mostshockabsorbersonnewvehiclesaregas
charged.Pressurizingtheoilinsidetheshock
absorberhelpssmooththerideoverrough
roads.Thispressurehelpspreventairpockets
fromformingintheshockabsorberoilasit
passesthroughthesmallpassagesinthe
shock.
Automotive Steering, Suspension, & Alignment, 4/e
By James D Halderman
Somegaschargedshockabsorbersuseasingletubethatcontainstwopistonsthat
separatethehighpressuregasfromtheworkingfluid.Singletubeshocksarealso
calledmonotubeorDeCarbonaftertheFrenchinventoroftheprincipleand
manufacturerofsuspensioncomponents.
RemoteReservoirShocks
Remotereservoirshockabsorbersareunitsdesignedforheavydutyusethatusea
separatecontainerfortheworkingfluid.
AirShocks/Struts
Airinflatableshockabsorbersorstruts
areusedintherearofvehiclestoprovide
propervehiclerideheightwhilecarrying
heavyloads.
Airinflatableshocksarestandardshockabsorberswithanairchamberwitha
rubberbagbuiltintothedustcover(top)oftheshock.
AirSprings
Someelectronicallycontrolledsuspensionsystemsuseairsprings.Abasicair
springconsistsofarubberairchamber,generallyclosedatthebottombyapiston
fittedintoacontrolarm,orbyastrutshockabsorber.
Someairspringsareineffectauxiliary
springsinsideacoilspringstrut.Inthese
designs,thecoilspringsupportsthe
weightofthevehicle,whiletheairspring
raisesorlowersthebodytoadjustride
heightaccordingtoload.
CoilOverShocks
Acoilovershockabsorberusestheforceofanexternalcoilspringtoboostthe
performanceofthebasicshockabsorber.
STRUTS
Astrutisasturdyshockabsorberthatis
alsoastructuralcomponentofthe
suspension.Astrutisasuspensionlink
aswellasashockabsorber.
MacPhersonStruts
TheMacPhersonstrut,whichisnamed
afterEarleS.MacPherson,who
developedthesuspensiondesigninthe
late1940sandpatenteditin1953,isthe
mostcommonlyusedtype.
ModifiedStruts
UnlikeaMacPhersonunit,amodifiedstrutdoesnotincludeaspringaspartofthe
assemblyandisusedinthefrontonsomevehiclesandontherearofothers.
BUMPSTOPS
Allsuspensionsystemshavealimit
oftravel.Ifthevehiclehitsalarge
bumpintheroad,thewheelsare
forcedupwardtowardthevehicle
withtremendousforce.
Automotive Steering, Suspension, & Alignment, 4/e
By James D Halderman
Insteadofallowingthemetalcomponentsofthesuspensiontohittheframeor
bodyofthevehicle,arubberorfoambumperisusedtoabsorbandisolatethe
suspensionfromtheframeorbody.
Thesebumpersarecalledbumpstops,suspensionbumpers,strikeout
bumpers,orjouncebumpers.Jouncemeansjolt.
SUMMARY
1.Thelighterthewheel/tirecombination,thelowertheunsprungweightandthebetterthe
rideandhandlingofthevehicle.
2.Allspringsincludingthecoil,leaf,andtorsionbartypesshareHooke'sLaw,which
statesthattheforceexertedbythespringisdirectlyproportionaltotheamountthespringis
deflected.
3.Allspringsaresimilartotorsionbars.Asthetorsionbarbecomeslongerorsmallerin
diameter,itbecomeseasiertotwist.Ifacoilspringiscut,theremainingspringisshorter,yet
stiffer.
4.Balljointsattachtocontrolarmsandallowthefrontwheelstomoveupanddown,aswell
asturn.
5.Suspensiondesignsincludeastraightorsolidaxle,twocontrolarmtypecalledanSLA
oraMacPhersonstrut.
6.Allshockabsorbersdampenthemotionofthesuspensiontocontrolrideandhandling.
REVIEWQUESTIONS
1.Listthetypesofsuspensionsandnametheircomponentparts.
3.Describethepurposeandfunctionofastabilizerbar.
3.Explainthedifferencebetweenaloadcarryingandafrictionballjoint.