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Adjustable Linear Shock Absorber Redesign. Matt Davis Joe O’Connor Ben Patterson Advisor: Mr. Lobaugh. Agenda. Sponsor Info Contract Details Design Problem Analysis of Competitors Shock Prototype Design Analysis Final Design Analysis. Modern Industries. Founded in 1946

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adjustable linear shock absorber redesign

Adjustable Linear Shock Absorber Redesign

Matt Davis

Joe O’Connor

Ben Patterson

Advisor: Mr. Lobaugh

agenda
Agenda
  • Sponsor Info
  • Contract Details
  • Design Problem
  • Analysis of Competitors Shock
  • Prototype Design Analysis
  • Final Design Analysis
modern industries
Modern Industries
  • Founded in 1946
    • Herbet S. Sweny
  • Industries Served
    • Machining
    • Heat Treating
    • Materials Research
    • Products Division
products division
Products Division
  • Currently 7 Shocks
    • None adjustable
    • Custom for each customer
  • Our Project
    • Adjustable linear shock absorber
    • “Catalog Version”
objective statement
Objective Statement
  • Study and reengineer an OEM linear shock absorber in order to provide a better working, more cost effective product that can be mass produced for a wide variety of commercial and industrial uses.
specific goals
Specific Goals
  • Improvements:
    • Better functionality – Adjustment Method
    • Material/design improvements
    • More cost effective product
scope limitations
Scope & Limitations
  • Scope
    • 3D models and working drawings of new designs
    • Simulate and test with FEA
    • Research material changes
  • Limitations
    • Only redesigning OEM linear 1B model
    • Materials limited to commercially available materials
deliverables
Deliverables
  • All concepts ideas
  • FEA results
  • Hand calculations to verify FEA
  • Working drawings of final design
  • Prototype
upper level courses
Upper Level Courses
  • MET 306 - Modeling
  • MET 320 – Hand Calculations
  • MET 415/425 – FEA of Designs
  • MET 432 – Internal Fluid
  • MET 457 – Product Improvements
  • MET 470 – Material Selection
  • QC 450 – FMEA
industrial shock absorbers
Industrial Shock Absorbers
  • Filled with hydraulic fluid
  • Designed to dissipate energy
    • Gradually bring a load to rest
  • Applications
    • Material Handling
    • Packaging Equipment
    • Small Robotics
    • Rotary Actuators
design ideas
Design Ideas
  • Before deconstruction
analysis of competitor shock
Analysis of Competitor Shock
  • Adjustment issues
  • Deconstruction
  • Testing
    • Physical
    • FEA
internal fluid flow
Internal Fluid Flow
  • Compression
  • Extension
energy absorbed comparison
Energy Absorbed Comparison

Data fit compared to linear regression

Prototype: R2 = 0.832

Competitor: R2 = 0.4546

competitors fea
Competitors FEA

Hoop Stress Using Cylindrical Axis

competitors fea1
Competitors FEA

VonMises Stress

improvements
Improvements
  • Adjustment Methods
  • Material Improvements
  • Manufacturing Costs
  • Mounting Options
final assembly
Final Assembly

Outer Cylinder

Foam Accumulator

Stepped Insert

O-Ring

Check Valve

O-Ring

Piston Shaft

Shaft Seal

Inner Cylinder

Top Cap

final design fea
Final Design FEA

Hoops Stress:

Inner Cylinder

Longitudinal Stress:

Inner Cylinder

final design fea1
Final Design FEA

Total Deformation:

Inner Cylinder

final design fea2
Final Design FEA

Hoops Stress:

Stepped Shelf Insert

Fluid Exit Point Stress - VonMises:

Stepped Shelf Insert

material cost analysis
Material Cost Analysis

**All estimates based on McMaster Carr pricing

summary
Summary
  • Improvements
    • Manufacturing
    • Materials
    • Design
  • Deconstruction
  • Testing/Analysis
  • Prototype Design
  • Final Design
questions
Questions

Special Thanks to Mr. Michael for assisting with MTS testing

prototype fea
Prototype FEA

Compressive Stress:

Piston Shaft

Total Deformation:

Piston Shaft

prototype fea1
Prototype FEA

Compressive Stress:

Outer Cylinder

Total Deformation:

Outer Cylinder

prototype fea2
Prototype FEA

Contact Pressure Between Inner Cylinder and Insert Shelf

competitors mts graphs 1hz
Competitors MTS Graphs (1Hz)

Shock Setting 0

Shock Setting 3

Shock Setting 6

Shock Setting 8

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