Design, Analysis and Experimental Validation for Fatigue Behavior of a Helical Compression Spring Used For a Two Wheeler Horn

Abstract

Almost all two-wheelers are provided with a facility of a horn to be used to make aware of the presence of the vehicle on road and to maintain a safe distance between two vehicles or to communicate for any other safety reasons. The horn is a crucial element as it is directly related to safety of the vehicle and the person using it. Thus the horn is most important element in the vehicle system and hence it is expected to function properly for a longer time. Most problems of failure of two wheeler horns are due to fatigue failure of spring element in warranty period. A finite element model for helical compression springs subjected to cyclic loads (compression) is developed for fatigue stress analysis. In the design modification of this kind of spring both the elastic characteristics and the fatigue strength have to be considered as significant aspects. A typical helical compression spring used for two wheeler horn is chosen for study under fatigue loading condition. Fatigue analysis is done in ANSYS 14.0 software. The results developed have been compared with the experimental observations. A new design modification is done by introducing another spring coaxially.