Calculations for springs and dampers : Front ride frequency Ff = 2.73 Hz Rear ride frequency Fr = 2.

1 Hz Motion Ratio = 0.57 Front sprung mass for single spring = 63.845 kg Rear sprung mass for single spring = 96.155 kg Front unsprung mass for one side = 15 kg Rear unsprung mass for one side = 15 kg Ride rates(rate of chassis with respect to ground)Front ride rate Krf = (2**Ff)2 *(front sprung mass) = 18785.031 N/m = 18.785 N/mm Rear ride rate Krr = (2**Fr)2 *(rear sprung mass) = 16740.568 N/m = 16.74 N/mm Suspension rate or suspension stiffness(rate of body with respect to wheel), Ks (N/mm) Let suspension rate for front be Ksf and for rear be Ksr. Tyre Spring rate Kt = 350 N/mm Then Kr = Ks*Kt / (Ks + Kt) 1/Kr = 1/Kt + 1/Ks 1/Ks = 1/ Kr 1/ Kt 1/Ksf = 1/ 18.785 - 1/ 350 Ksf = 19.85 N/mm 1/Ksr = 1/ 16.74 - 1/ 350 Ksr = 17.58 N/mm

Spring Rate Let front spring rate be Ksprf and rear be Ksprr. Ks = (Motion ratio)2 * Kspr Ksprf = 61.095 N/mm Ksprr = 54.108 N/mm Front Spring Dimensions Material used = Oil hardened and tempered spring steel wire(unalloyed) of VW grade Ksprf = N/mm Max. Deflection of tyre on bump/rebound = 1.75 inch (let) = 44.45 mm So Max. deflection of spring max. = Motion Ratio * 44.45 = 25.337 mm Max. Force needed for this deflection Pmax.= Ksprf * max. = 1547.964 N Shear Stress Equation is = 8(Kw)PC/ d2 where Kw is Wahl factor. For C= 6, Wahl factor = 1.253 (By Hit and Trial method),For spring wire diameter d= 7mm and Spring index(C=D/d)= 6 ,Max. Shear stress that can be taken by spring is 604.8 N/mm2 which is less than 650 N/ mm2) (For this diameter and spring index, Max.allowable shear stress =0.5 of Tensile Strength=650 N/mm2) Hence our spring design is safe. Mean coil diameter D = C*d = 42 mm For number of active coils N, N=Gd/8(C3)Ksprf G = Shear Modulus of Rigidity = 81370 N/mm2 N = 5.4 = 6

Assuming both square and ground ends ,Inactive coils = 2 and total number of coils Nt= 6+2 = 8 Solid length = Nt * d = 56 mm Assuming axial gap between adjacent coils at max. deflection to be 2 mm ,total axial gap = (Nt-1)*2 = 14 mm Actual max.deflection = 8P(C3)N/Gd = 28.18 mm Free length = solid length + total axial gap + actual max.deflection = 98.18 = 99 mm Pitch = Free length/(Nt-1) = 14.14 mm Simillarly for Rear Spring Material used = Oil hardened and tempered spring steel wire(unalloyed) of VW grade Ksprr = 54.108 N/mm Max. Deflection of tyre on bump/rebound = 1.75 inch (let) = 44.45 mm So Max. deflection of spring max. = Motion Ratio * 44.45 = 25.337 mm Max. Force needed for this deflection Pmax.= Ksprf * max. = 1370.94 N Shear Stress Equation is = 8(Kw)PC/ d2 where Kw is Wahl factor. For C=5 , Wahl factor = 1.311 (By Hit and Trial method),For spring wire diameter d= 6mm and Spring index(C=D/d)= 5 ,Max. Shear stress that can be taken by spring is 634.66 N/mm2 which is less than 670 N/ mm2 (For this diameter and spring index, Max.allowable shear stress =0.5 of Tensile Strength=670N/mm2 ) Hence our spring design is safe. Mean coil diameter D = C*d = 30 mm For number of active coils N, N=Gd/8(C3)Ksprf G = Shear Modulus of Rigidity = 81370 N/mm2 N = 9.03 = 10 Assuming both square and ground ends ,Inactive coils = 2 and total number of coils Nt= 10 + 2 = 12 Solid length = Nt * d = 72 mm Assuming axial gap between adjacent coils at max. deflection to be 2 mm ,total axial gap = (Nt-1)*2 = 22 mm Actual max.deflection = 8P(C3)N/Gd = 28.08 mm Free length = solid length + total axial gap + actual max.deflection = 122.08 = 123 mm Pitch = Free length/(Nt-1) = 11.18 mm

Damper Calculations :For front side Critical Damping Coefficient for body = (4*Ksprf*front sprung mass on one side)0.5 = 3950 Ns/m Critical Damping Coefficient for wheel = (4*(Ksprf+Kt)*front unsprung mass on one side)0.5 =4966.45Ns/m Natural Frequency for sprung mass = (Ksprf/sprung mass on one side)0.5 = 4.924 Hz

(From Fundamentals of Vehicle Dynamics by Thomas D. Gillespie) More damping ratios provide much better body control than a passenger car (less overshoot), and faster response than critical damping but reduce ride comfort. Less damping ratios give more ride comfort. Damping ratio = 0.4 Percent of critical body = 0.4 Percent of critical wheel = 0.3 Compression Damping = 1580 Ns/m Rebound/Compression Damping ratio = 1.6:1 Rebound Damping = 2528 Ns/m

For rear side Critical Damping Coefficient for body = (4*Ksprr*rear sprung mass on one side)0.5 = 4561.9 Ns/m Critical Damping Coefficient for wheel = (4*(Ksprr+Kt)*rear unsprung mass on one side)0.5 =4924.1Ns/m Natural Frequency for sprung mass = (Ksprr/sprung mass on one side)0.5 = 3.78 Hz Damping ratio = 0.35 Percent of critical body = 0.35 Percent of critical wheel = 0.32 Compression Damping = 1596.67 Ns/m Rebound/Compression Damping ratio = 1.6:1 Rebound Damping = 2554.68 Ns/m Since Roll and Pitch deflection are less than that in ride bumps/droops, so Ride damping is sufficient.