Customers increasingly prioritize safety and ride comfort, making these factors critical to the success of modern automotive design. The McPherson suspension system, widely used in passenger vehicles, is known for its simplicity and reliable performance. However, instances of premature failure and sudden fracture have highlighted the need for design improvements. Among the suspension components, the strut mount and the spring are particularly susceptible to failure due to continuous heavy loading and vibrations induced by uneven road conditions. To address these issues, this study employs simulation tools such as Onshape and ANSYS to evaluate various design modifications to the suspension system and compare them with an established baseline model. Numerical analyses conducted on different spring geometries and parameters reveal that wave springs are capable of absorbing higher loads while exhibiting lower deformation under identical loading conditions compared to conventional coil springs. Although a slight increase in vibration-induced deformation is observed in wave springs, the results suggest that with further optimization, wave springs can effectively mitigate dynamic disturbances and offer improved durability and service life over traditional coil-spring-based shock absorber systems.
Gupta et al. (Thu,) studied this question.