Possibilities of Coil Springs and Fiber‐Reinforced Suspension Parts

## Abstract Helical compression springs (coil springs) have represented the best spring design for the vertical dynamics of passenger cars. They took over suspension functions and because of their advantages regarding weight and installation space they replaced leaf springs almost completely. This chapter contents a summary of conventional analytical as well as numerical methods of spring calculation. The numerical spring calculation and its usage for a new spring design with a homogenized stress distribution are shown. This new generation spring design is explained for the application on side load springs used in McPherson struts and rear axle spring where the spring seats deflect along a spatial curve. The new generation spring design offers a significant weight reduction combined with an increased robustness. The robustness of springs can be further increased using a method for improving the mechanical properties of the rim of the wire. The surface layer modification is using an inductive hardening and tempering process of the spring wire, which allows a hard core and a tough rim. Moreover, measures to improve the properties by alloying are described. Finally, this chapter contents the application of fiber composite materials for springs. While leaf spring is an optimal application for unidirectional glass fibers, suspension springs such as coil spring are not that much optimal because of complex stress situation and difficult geometry, which does not allow efficient and automated production methods. auto001 1 auto002 12 auto003 36 auto004 48 auto006 60 auto007 72 auto008 83 auto010 99 auto012 113 auto014 124 auto015 141 auto016 158 auto021 177 auto022 194 auto023 209 auto024 225 auto025 247 auto026 258 auto028 270 auto029 285 auto030 297 auto032 315 auto034 336 auto035 353 auto037 368 auto040 377 auto041 395 auto042 413 auto046 422 auto047 428 auto048 448 auto049 463 auto050 474 auto051 485 auto053 500 auto054 515 auto055 525 auto061 537 auto062 551 auto063 567 auto064 586 auto065 606 auto066 621 auto067 639 auto068 649 auto069 666 auto073 683 auto075 698 auto077 707 auto081 726 auto083 744 auto084 761 auto086 771 auto090 787 auto091 802 auto092 826 auto095 844 auto096 859 auto097 870 auto098 876 auto102 891 auto103 910 auto104 917 auto106 934 auto107 948 auto108 983 auto111 999 auto112 1013 auto113 1024 auto114 1039 auto115 1053 auto116 1072 auto117 1081 auto118 1089 auto119 1115 auto120 1146 auto122 1182 auto123 1195 auto124 1208 auto125 1227 auto126 1254 auto127 1269 auto129 1278 auto130 1299 auto131 1316 auto132 1334 auto135 1355 auto136 1365 auto137 1381 auto138 1393 auto139 1410 auto140 1426 auto141 1449 auto142 1465 auto143 1479 auto146 1505 auto147 1521 auto148 1543 auto149 1557 auto150 1574 auto151 1592 auto152 1618 auto153 1632 auto155 1651 auto157 1677 auto159 1690 auto160 1706 auto162 1723 auto163 1738 auto164 1755 auto165 1768 auto166 1780 auto167 1796 auto168 1804 auto169 1814 auto170 1842 auto172 1855 auto174 1863 auto175 1875 auto176 1902 auto177 1915 auto178 1930 auto179 1939 auto183 1950 auto184 1973 auto185 1991 auto186 2002 auto188 2014 auto189 2024 auto192 2032 auto193 2051 auto194 2065 auto195 2081 auto196 2091 auto197 2109 auto200 2119 auto201 2132 auto202 2142 auto203 2154 auto204 2166 auto205 2176 auto206 2193 auto207 2208 auto208 2223 auto210 2240 auto211 2262 auto212 2281 auto213 2294 auto214 2309 auto215 2318 auto216 2331 auto217 2341 auto218 2354 auto224 2363 auto225 2371 auto226 2387 auto227 2404 auto228 2421 auto229 2427 auto231 2434 auto232 2449 auto233 2458 auto234 2465 auto237 2474 auto238 2479 auto241 2492 auto245 2508 auto248 2524 auto252 2540 auto254 2553 auto259 2565 auto260 2577 auto273 2600 auto275 2617 auto279 2623 auto283 2629 auto284 2634 auto285 2643 auto286 2657 auto287 2680 auto288 2691 Provides for the first time a large, unified knowledge base laying the foundation for advanced study and research in automotive engineering. The Encyclopedia of Automotive Engineering has been developed in conjunction with FISITA, the umbrella organisation for national automotive societies in 37 countries around the world, representing over 190,000 automotive engineers. Through extensive cross-referencing and search functionality it provides a gateway to detailed but scattered information on best industry practice, engendering a better understanding of interrelated concepts and techniques that cut across specialized areas of engineering. Beyond traditional automotive subjects the Encyclopedia addresses green technologies, the shift from mechanics to electronics, and the means to produce safer, more efficient vehicles within varying economic restraints worldwide. The work comprises nine main parts: (1) Engines: Fundamentals (2) Engines: Design (3) Hybrid and Electric Powertrains (4) Transmission and Driveline (5) Chassis Systems (6) Electrical and Electronic Systems (7) Body Design (8) Materials and Manufacturing (9) Intelligent Transport Systems. *Authoritative coverage of the wide-ranging specialist topics encompassed by automotive engineering. *An accessible point of reference for entry level engineers and students who require an understanding of the fundamentals of technologies outside of their own expertise or training. *Invaluable guidance to more detailed texts and research findings in the technical literature *Available both as a fully searchable, updating online resource, and in a print edition (publishing January 2015) comprising six volumes and over 4000 pages. An essential resource for libraries and information centres in industry, research and training organizations, professional societies, government departments, and all relevant engineering departments in the academic sector. Readers/users will include: Professional engineers and technical staff in industry; senior undergraduate and postgraduate level students and researchers; educators and trainers; industry analysts and researchers.--Provided by publisher A Choice Oustanding Academic Title The Encyclopedia of Automotive Engineering provides for the first time a large, unified knowledge base laying the foundation for advanced study and in-depth research. Through extensive cross-referencing and search functionality it provides a gateway to detailed but scattered information on best industry practice, engendering a better understanding of interrelated concepts and techniques that cut across specialized areas of engineering. Beyond traditional automotive subjects the Encyclopedia addresses green technologies, the shift from mechanics to electronics, and the means to produce safer, more efficient vehicles within varying economic restraints worldwide. The work comprises nine main (1) Fundamentals (2) Design (3) Hybrid and Electric Powertrains (4) Transmission and Driveline (5) Chassis Systems (6) Electrical and Electronic Systems (7) Body Design (8) Materials and Manufacturing (9) Telematics. 6 Volumes (http://www.automotive-reference.com) www.automotive-reference.com An essential resource for libraries and information centres in industry, research and training organizations, professional societies, government departments, and all relevant engineering departments in the academic sector.