This document describes modeling and simulation of a shock absorber test rig. It discusses the need to minimize vibrations in vehicles for improved comfort and handling. The objective is to design a universal process to measure shock absorber performance through mathematical modeling, FEM analysis, physical tests on a test rig, and Python analysis. The test rig was designed to test shock absorbers up to 3000kg with 40mm of displacement. Simulation results from Python analysis showed displacement and load values within 3-15% of physical test rig values, demonstrating the model's ability to simulate the rig. The conclusion is that this process can help evaluate damping system performance for research and development.

1. Modeling & Simulation of Shock-Absorber
Test Rig
UNDER THE SUPERVISION OF
DR. PRASHANT CHAUHAN
DEPARTMENT OF MECHANICAL ENGINEERING
JSS ACADEMY OF TECHNICAL EDUCATION, NOIDA
SUBMITTED BY :
Ankit Kumar Dixit
Aradhya Saxena
Arpit Gupta
Chandransh Pandey
Group No. D-11

2. INTRODUCTION
 Vibrations are one of the major losses that mechanical engineers have to deal with. It cannot be
totally removed but it can be minimized.
 For better vehicle handling vibration control of vehicle is a major challenge which is influenced
by the harmful effects of vibrations caused by road irregularities on driver's comfort.
 A shock absorber ("damper") is a mechanical or hydraulic device designed to absorb and damp
shock impulses. It does this by converting the kinetic energy of the shock into another form of
energy (typically heat) which is then dissipated.

3. WHAT IS SHOCK ABSORBER ?

4. PROBLEM STATEMENT
For vehicle, it is always challenging to maintain simultaneously a high standard of ride comfort,
vehicle handling under all driving conditions. It is necessary to determine the characteristics of
damping system for various computational and analysis purpose which can be further utilized in
Research & Development of shock-absorbers.
This project aims towards defining a universal testing procedure for shock absorbers.
Shock absorbers will undergo a specific test sequence. All the tests will be predefined and
described in detailed. In order to properly investigate the variable controls of a shock absorber
and enable greater performance of the suspension system, a more detailed and a universal testing
procedure is needed.

5. OBJECTIVE
To design and develop a Universal Process to
measure the performance and behaviour of a
vibration-damping system.
The process involves obtaining
graphical characteristics from:
1. Mathematical Modeling
2. FEM Analysis
3. Physical Tests on test rig
4. PYTHON Analysis
The Characteristics Are Then Studied And
Compared With Each Other And Performance Of
The System Is Evaluated. Further A Report Of The
Damping System Is Generated.

6. PROCESS
Damping System
Defining Parameters &
Limits
FEM
Mathematical
Modeling
Physical Tests on
Test Rig
Python
Impulse Testing
Report Generation
Endurance Testing
Characteristics

7. QUARTER-CAR MODEL
X1
X2
W

8. SIMULINK MODEL

11. Load Cell
Motor Driver
Specimen
LVDT
Crankshaft
TEST RIG FEATURES
Maximum Load: 3000KG
Maximum Displacement: 40mm
Motor Specs: 25HP
Arrangement: Slider Crank
Manufacturer :
Autotest Mechanisms Pvt Ltd
Nagloi, Delhi

12. Cycle No. X-Axis +ve
(mm)
X-Axis -ve
(mm)
Compression
Load
(Kg)
Tensile
Load
(Kg)
Velocity
(mm/sec)
Frequency
(Hz)
1.000 10.098 -9.108 580.478 -641.379 105.774 1.667
2.000 10.149 -9.222 579.138 -646.089 105.774 1.667
3.000 10.177 -9.181 576.496 -648.435 103.686 1.667
4.000 10.262 -9.144 575.541 -649.170 103.686 1.667
5.000 10.166 -9.117 573.123 -651.161 103.686 1.667

13. CONTROL SYSTEM

14. VIDEOS

15. VIDEOS

16. SIMULATION (FUSION 360)

19. PROGRAMMING ON PYTHON

20. CHARACTERISTICS FROM PYTHON
INPUT OUTPUT

21. COMPARISON B/W SIMULATION &
INDUSTRIAL VALUES
Displacement
(Ideal)
Displacem
ent
(Actual)
Load
(Simulation)
Load
(Actual)
Error
%
10 10.098 660 641 2.9%
-10 -9.1 660 580.478 13.7%

22. CONCLUSION
For various computational and analysis purpose it is necessary to determine the characteristics of a damping
system which can be further utilized in Research & Development of shock-absorbers. Quality checking is
required to test that prototypes or samples of production dampers meet their specifications within tolerance and
are adequately consistent one to another. It can also help for the dampers to be rated on the basis of their
performance so that comparing various shock-absorbers can be made simpler. This will help the engineers to
design & choose a better damping system for their vehicles.
It is a thorough analysis and a full report generation approach which will help the industry to know more about
the shock-absorbers. The concept can be materialized and implemented to obtain experimental results and
development of data-base in future and it will benefit future researches and complement other projects based on
suspension systems.
Results also proved that successful calibration can be achieved with the test rig machine using various tools
such as Python, MATLAB & FEA. As required the project delivered a method to simulate the shock absorber
test rig. The results vary about 15% and extreme values vary about 3-6%. The mathematical model can be
refined and other parameters can be included. It will give results closer to the practical values.

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26. BIBLIOGRAPHY
1. www.sciencedirect.com
2. https://journaltool.asme.org
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27. THANK YOU !