Automobile Engineering 15ME63A

UNIT-5 SUSPENSION SYSTEMS, WHEELS & TYRES (30 MARKS)

R.1] List the elements of suspension system.

 Coil springs
 Leaf springs
 Shock absorbers
 Spring shackles
 Stabilizer

R.2] List the types of Automobile wheels.

 Disc wheel
 Spoke wheel/Wire wheel
 Light alloy cast or forged wheel

R.3] List the essential requirements of wheels.

 The wheels should be able to take twice the load of vehicle.
 Wheels should give cushioning effect and cope with steering control.
 They should be lightest possible so that the unsprung weight is less.
 They should absorb the retarding force when the breaks are applied.
 They should be balanced both statically as well as dynamically.
 Their material should not deteriorate with weathering and age.
 They should be possible to remove or mount the wheels easily.
[Un sprung weight: It is the weight of all the parts between the spring and rod and the portion of spring
weight itself]

R.4] List the factors affecting the tyre life.

The factors which influence tyre life are as follows:
 Inflation Pressure
 Loads and Loading practices
 Driving Speed
 Wheel Alignment
 Wheel Balancing
 Tyre rotation pattern
 Road Conditions
 Seasonal Effects
 Manner of driving
 Brakes adjustments
U.1] Explain the elements of suspension system.
The main components of suspension system are the springs, shock absorbers and struts.
 Springs:
The springs support the weight of the vehicle, maintain ride height and absorb road shock
caused by bumps or dips in the road. The coil spring is the most common and may be used at both the

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front and rear of the vehicle. The leaf spring is made of several steel plates of different lengths and is
commonly used at the rear of the vehicle.
 Shock absorbers:
Shock absorbers provide resistance by forcing hydraulic fluid through valves in the piston as it
moves up and down which dampen movement of the vehicles springs as they compress and rebound
during vehicle travel. The amount of resistance depends on how fast the suspension moves. Without
shock absorbers vehicle would continually bounce, making it difficult to control.
 Struts:
Unlike shock absorbers, struts are a major structural part of the suspension. Struts perform two
main jobs. First, they act like a shock absorber to dampen the movement of the springs as they
compress and rebound. Secondly struts provide structural support for the vehicles suspension, support
the spring and hold the tire in an aligned position.

U.2] Explain leaf spring with a neat sketch.

 The spring consists of number of leaves called blades. The blades vary in length as shown in figure.
 The lengthiest blade has eyes on its ends. This blade is called master leaf.
 All the blades are bound together by means of steel straps.
 The spring is supported on the axle, front or rear by means of a U-bolt. One end of the spring is
mounted on the frame with a simple pin, while on the other end, connection is made with a shackle.
 When the vehicle comes across a projection on the road surface, the wheel moves up, deflecting the
spring. This changes the length between the spring eyes.
 If both the ends are fixed, the spring will not be able to accommodate this change of length. This is
provided for by means of a shackle at one end which gives a flexible connection.

U.3] Explain Coil spring with a neat sketch.

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Automobile Engineering 15ME63A

 The coil springs are used mainly with independent suspension, though they have also been used in
the conventional rigid axle suspension as they can be well accommodated in restricted spaces.
 The energy stored per unit volume is almost doubled in the case of coil springs than the leaf springs.
 Coil springs do not have noise problems, nor do they have static friction causing harshness of ride
as in case of leaf springs.
 The spring takes the shear as well as bending stresses.
 The coil springs, however, cannot take torque reaction and side thrust, for which alternative
arrangements have to be provided.

U.4] Explain telescopic shock absorbers with a neat sketch.

Construction:
 A telescopic shock absorber derives its name from
tubular shape of early telescopes used in ancient times.
 They are 2 types viz. mono tube and twin tube
type. The twin type shock absorber is as shown in the
figure.
 Rod G is attached to a 2 way valve A; while
another similar 2 way valve B is attached at the lower end
of cylinder C.
 There is a fluid (oil) in the space between the valve
A and B and also in the annular area between cylinder C
and tube D.
 H is a gland in the head J. The eye E is connected
to axle and eye F is connected to the chassis frame.

Working:
 When the vehicle come across a bump then the lower eye ‘F’ moves up, by this the oil below ‘A’
will move to upper side of ‘A’ through it.
 Since there will be resistance to the flow of oil through ‘A’ it exerts pressure on the valve ‘B’ also.
Thus the oil flows through ‘B’.
 This passing of oil through ‘A’ and ‘B’ valves will be very slow; due to resistance this gives
damping effect.
 Similarly for downward movement of the eye ‘F’, due to road irregularity, the oil will move from
the upper side valve ‘A’ to the lower side and also from lower side of ‘B’ to its upper side.
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Automobile Engineering 15ME63A

U.5] Explain pressed steel disc wheels

Disc wheel consist of steel rim and steel disc.

The rim is rolled section sometimes invented but usually welded to the
flange of the disc of steel rim, which generally well based to receive the
tyre and pressed steel disc.

The rim and disc may be integral, permanently attached. When the bead
of the tyre is resting in the well , it is possible to pass the tyre over the
opposite edge of the rim.

The rim has well, which allows tyre to go over the edge of the opposite
side of the rim

A 50 taper has given on edge of the rim on which tyre seats

It is commonly used in heavy vehicles, cars, buses, trucks, etc.

This type of wheel is simple, cheap and robust in construction.

U.6] Explain Wire/spoke wheels.

 The spoke has a separate hub, which is attached to the rim through a number of wire spokes.
 The spokes carry the weight, transmit the driving and braking torques and to with stand side forces
while cornering in tension.
 Spokes are long thin wires and as such these cannot takes any compressive or bending stresses. All
types of loads are sustained by the spokes in tension .

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 The spokes are mounted in a complicated criss-cross fashion. The side forces on cornering are taken
up by the spokes forming triangular arrangement.
 The initial tension of the spokes can be adjusted by means of screw nipples which is also serve to
secure the spokes to the rim.
 The hub is provided with internal splines to correspond to the splines provided on the axle shaft.
 The advantage of this type of wheel is light weight and high strength and above all it provides much
better cooling of the brake drum.
 It is also very easy to change the wheel when required, because only one nut has to be opened
.However wire wheel are expensive due to their intricate construction.

U.7] Explain Cast light alloy wheels

 The latest trend in case of automobile wheels is the use of wheels made
from aluminum or magnesium alloys cast wheels are generally used for cars
while forged wheels are preferred for wheels of heavier vehicles.
 The main advantage of light-alloy wheels is their reduced weight
 A magnesium alloy wheel weighs about 50 per cent of a steel wheel and
about 70 per cent of an aluminum alloy wheel for similar strength.
 Moreover, light alloys have better conductivity of heat which helps the
wheels to dissipate heat generated by the tyres or brakes and thereby run cooler.
 Magnesium alloys have high impact and fatigue strength so that they can
stand vibrations and shock loading better. However, being tune to corrosion,
these have to be given some protective coating.
 Aluminum alloys do not have high resistance to vibration and shock as in
case of magnesium alloys, but these are relatively easier to cast or forge and also
less tune to corrosion.
 Generally, aluminum alloys are used for cars sports and racing cars
usually have magnesium alloy wheels. Higher cost is the only disadvantage of
light alloy wheels.

U. 8] Explain radial tyre.

 In this ply cords run in the radial direction i.e. in the direction of the
tyre axis. Over this basic structure, run a number of breaker strips in the
circumferential direction.
 The material for the breaker strips must be flexible but inextensible, so
that no change of circumference takes place with change of the amount
of inflation.
 Without the breaker strips, radial plies would give very soft ride, but
there will not be any lateral stability.
 The extensible breaker strip behaves like a girder in its own plane and
provides the directional stability

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Automobile Engineering 15ME63A

U.9] Explain cross-ply tyre.

 In this type, the ply cords are woven at an angle (30deg – 40deg) to
the tyre axis.
 There are two layers which run in opposite directions.
 However, the cords are not woven like wrap and weft of ordinary
cloth because that would lead to rubbing of the two layers and thus
produce heat which would damage the tyre material

U.10] Explain tubed tyres.

 Figure shows a simplified form the cross section of such

a tyre. It consists of two main parts, viz. the carcass and the
tread.
 The carcass is the basic structure taking mainly the
various loads and consists of a number of plies wound in a
particular fashion from the cords of rayon or any other suitable
material.
 In order to prevent the tyre from being thrown off the
rim, the plies are attached to two rings of high tension steel wire.
These rings are made to fit snugly against wheel rim thereby
anchoring the tyre to the rim. These rings are called beads.
 The tread is the part of the tyre which contacts the road
surface when the wheel rolls. It is generally made of synthetic
rubber.
 Between the head and the tread the outer rubber covering of the carcass is called side wall. The
sidewalls are designed to flex and bend without cracking when subjected to continuous deflection
while running. In other words, the sidewall material must have high fatigue strength.
 At the inner edges, beads are formed by reinforcing with steel wires. This provides the tyre with
strong shoulders for bearing against the wheel rim. All plies are tied to the beads which prevent any
change of shape.
 Inside the tyre, there is a tube which contains the air under pressure. The tube being very thin and
flexible, takes up the shape of the tyre cover when inflated. A valve stem is attached to the tube for
inflating or deflating the same.

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Automobile Engineering 15ME63A

U.11] Explain tubeless tyres.

This type of tyre does not need a separate tube; instead the air under pressure is filled in the tyre for which
purpose a non-return valve is fitted to the rim. The inner construction of the tyre is almost same as that of
tube tyre, except that it is lined on inside with a special air-retaining liner.
The tubeless tyres possess following advantages over the conventional tubed tyres.
1. Temporary puncture repairs are made with out removing the wheel.a rubber plug is inserted at the
place of puncture.
2. Air is retained for longer period even after punctured.
3. Tubless tyres are lighter in weight and cooles faster.
4. Tubless tyres imparts more resistance to impact load.
5. Better air seeling qualities are obtain.
6. It is simple in assemble only tyre has to be fitted on rim
A.1] Identify the importance of a suspension system in a vehicle.
The automobile frame and body are mounted on the front and rear axle not directly but through the
springs and shock absorbers. The assembly of parts, which perform the isolation of parts from the road
shocks, may be in the forms of bounce, pitch and roll is called suspension system.
Functions of suspension system
 To prevent the vehicle body and frame from road shocks.
 To give stability to the vehicle.
 To safeguard the passengers and goods from road shocks.
 To give the good road holding while driving, cornering and braking.
 To give cushioning effect.
 To provide comfort.

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A.2] Making use of a sketch explain McPherson suspension system.

 In this layout only lower wishbones are used. A strut containing shock absorber and the spring
carries also the stub axle on which the wheel is mounted.
 The wishbone is hinged to the cross member and positions the wheel as well as resists accelerating,
braking and side forces.
 Further, the camber also does not change when the wheel moves up and down.
 This type of suspension gives the maximum room in the engine compartment and is therefore
commonly used used on front wheel drive cars.
 This is claimed to provide increased road safety, improve ride comfort and light and self-stabilizing
steering.
A.3] Making use of a sketch explain wishbone suspension system.

 In this type of suspension system coil springs are mostly used between the two suspension arms and
are controlled with frame and at the open ends of the upper and lower wishbones which are
connected to the chassis frame.
 The upper arm is shorter than lower one. This keeps the wheel track constant.
 The closed ends of the both arms are connected with steering knuckle, supported by means of
kingpin.
 A coil spring is placed in between the lower suspension arm and frame.

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A.4] Identify the importance of wheel alignment and balancing in a vehicle.

The Importance of Wheel Alignment
 It is very important that motorists get their wheels aligned to maximise the lives of their tyres as
much as possible. Tyres that have not been aligned properly are more prone to excessive tyre wear
and will result in change of tyres a lot more regularly, resulting in pay out costs that are
unnecessary.
 Motorists will be able to tell if their wheels have not been aligned correctly when the vehicle will
not move straight when the steering wheel is not being held. If this occurs, find a mechanic who can
align the wheels as it could lead to some problems related to suspension and vibrations while
driving.
 When tyres are not aligned, it can also put safety at risk. Improper alignment of the vehicle’s wheels
will also result in poor cornering and handing of vehicle and this will make it less safe for the driver
and its passengers, especially in icy and wet conditions.
 Also, drivers will have to make more of an effort driving the vehicle when the tyres are not aligned
as the vehicle will tend to steer to one side which will mean that the driver will have to constantly
correct it when driving. This means it requires an increase in concentration and effort at all times in
order to drive safely and especially with long journeys, can result in the driver becoming tired
quicker and become unsafe for everyone.
The Importance of Tyre Balancing
 This process is performed in order to ensure that all of the tyres are balanced with the wheel weights
to ensure the smooth running of each of the tyres. When there is an imbalance, the steering wheel
will rock back and forth during the high speed drive.
 Tyres are said to be unbalanced when certain tyres are wearing at a faster rate than others and this
need to be corrected as soon as possible.
 It is importance that all tyres are balanced, if not vibrations occur when travelling at certain speeds
and this is very dangerous for the driver and its passengers. These vibrations also result in stress
being created in the lower ball joints, axles and other essential parts of the vehicle.
 Unbalanced tyres will also result in an increase in the tyre wear. This is because to compensate for
the added stress on the tyres that the imbalance has created, the tyres start to wear from the edges,
whereas with balanced tyres, they will wear from the middle.

Miscellaneous questions:

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Automobile Engineering 15ME63A

1] Explain Air Suspension System with a block diagram

 Air suspension systems are coming into prominence because of certain advantages they possess
over the conventional metal springs.
 The layout of an air suspension system is shown in the figure. The four air springs are mounted on
the same position where generally the coil springs are mounted.
 An air compressor takes the atmospheric air through a filter and compresses it to a pressure of about
240 MPa, at which pressure the air in the accumulator tank is maintained, which is also provided
with a safety relief valve.
 This high pressure air goes through the lift control valve and the leveling valves, to the air springs
as shown.
 The lift control valve is operated manually by means of a handle on the control panel, through a
cable running from the valve to the handle.
2] Comparison of radial-ply and cross-ply tubes
Radial ply Cross ply
In radial ply type, the cords of tyre run in radial In cross ply type, alternate layers of cords run in
direction opposite direction
The cord ply are woven in radial direction of tyre The cord ply are woven at angles of 30-40 degrees
axis to the tyre axis
Radial tyre are provided with breaker strip, thus a There is no breaker strip in this tyre. Thus
continuous flat contact is possible with the road continuous grip with road surface is not possible
surface
This tyre has low rolling resistance, tjus better fuel The cross ply has more rolling resistance as
efficiency compared to radial ply
This tyre provides better directional stability This tyre has wobbling characteristics

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This tyre has greater sidewall flexibility and treads sidewall flexibility and treads stiffness is lesser as
stiffness compared to radial ply type

3] Write a note on Tyre specifications

The tyre are specified and designated by the nominal size of their sectional width and the rim diameter
E.g : 125J x 225 means a tyre having 125 mm as rim width with wheel diameter as 225mm.
For radial ply tyre, a letter ‘R’ standing for redial ply construction is used along with marking as
154 R 14 where 14 is nominal diameter in inch code and 145 mm code and .
E.g : 8.25x20 x10 PR
The width or thickness of tyre from shoulder to shoulder is 8.25 inch.
Diameter of the bead circle , which fit on the rim is 20 (inch)
PR means ply rating 10 PR means the tyre consist of 10 plies.
Scooter tyre consist of 1-4 plies, car tyre consist of 4-6 plies. The light truck back tyres has 6-10 plies
etc.

4] Explain Static and dynamic balancing of automobile wheels

Wheel balancing is the placement of wheel weights around a tyre and wheel assembly to counteract the
centrifugal forces acting upon heavy area. A properly balanced wheel will roll smoothly at varying speeds
without hoop by unbalance. For good steering, the front wheels and tyres should be perfectly balanced. Due to
uneven tread wear with probable patches on the inner tube and gaiters on the tyre, a certain amount of
unbalance always exists. This balancing of wheel is very essential to prevent front wheel wobbling; otherwise
this may results in hard steering.
Static Balance
This is the simplest way of checking to inspect and rectify. If any one of the front wheels is Jacked
up and rotated slowly it will come to rest with the heaviest portion at the lowest point. Having ascertained
the location of the heaviest portion, it must be marked with the chalk. But incase of wire wheel short length
of lead wire can be wrapped around one or more spokes at a point opposite to chalk mark. The length of the
wire will be sufficient to obtain satisfactory balance.
Dynamic Balance
A wheel may be in perfect static balance but dynamically unbalanced. The dynamic unbalance due
to fact that when the wheel is rotated, the centrifugal forces acting in different heavy spots are unbalanced
because the forces are not acting through the same line.
This would result in rotation of the two wheel axis around the king pin in different directions .This effect is
known as wheel shimmy causing the wheel to flap around the king pin. For dynamic balancing the centre of
gravity of wheel must coincide with the axis of wheel rotation. This is only possible if the masses of the wheel
and tyre are properly distributed.
To adjust the dynamic unbalance suitable weight is attached to the inner and outer side of the wheel rim,
there by correcting the dynamic unbalance with disturbing the static balancing.

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