Comparison of Iron and Steel Helical Suspension Springs for Mechanical Load Management Using Finite Element Method

Springs are stretchy objects that can store mechanical energy by changing their shape when a force is applied and returning to their original shape when the force is removed. Springs are very useful in many applications, such as active suspension systems for vehicles, which can make the ride smoother and safer. This study aims to model and evaluate the best material for such a system. The investigation utilizes COMSOL Multiphysics software to model the deformation and stretching of steel and iron suspension springs found in spiral two-wheelers. The study also explores the nonlinear dynamic behavior of spiral springs with higher mass, assuming constant pitch and elasticity. The simulation results are compared for both steel and iron springs with those obtained by the finite element method. The study found that steel springs have better suspension performance than iron springs, as they can bend more without breaking and spread the force evenly along the coil. Steel springs also have higher corrosion resistance than iron springs, which means they can last longer and look better. Therefore, steel springs are more suitable for helical suspension systems in terms of weight reduction, energy efficiency, and cost-effectiveness and steel springs are a smart choice for improving the operation and lifetime of vehicles.