Analysis of Helical Joint Suspension System with 6 Sigma Tool

Conventional helical coil suspensions are heavier and have lower energy absorption characteristics. To improve vehicle mileage and ensure a smoother ride there is a need to develop a new design of helical coil suspensions that are lighter in weight and possesses better energy absorption characteristics. Structural analysis using the FEA method on new design of helical coil (varying cross-section) suspension is performed using ANSYS software and composite material is employed to achieve better performance of helical coil suspensions. The CAD model of helical coil suspension is developed using ANSYS design modeller software and structural analysis is conducted in workbench. The optimization variables are selected to respond to the surface optimization of suspension. The design points are generated using Taguchi DOE (Design of Experiments) and stresses, deformation, mass are evaluated for each design point. The 3D response surface plots, sensitivity plots are generated and the component is further subjected to 6 sigma evaluation for robust designing. The 6-sigma evaluation of suspension would provide us sigma value for each design point with a probability distribution and parts that are likely to fail.