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This document is property of Kaz Technologies Not authorized for use by outside organizations
Damper Basics
It is thought by many that dampers are a
black art
That there is some magic to developing
and tuning dampers
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Damper Basics
We are here to dispel those myths and give
you tools to develop dampers
However, there is art in damper tuning
The art is optimizing the damper using
engineering knowledge &the proper tools
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This document is property of Kaz Technologies Not authorized for use by outside organizations
Course Outline
Damper Basics
Inside the Damper
Damper Testing
Damper Design
Advanced Tools
The Last Word
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KAZ Technologies
KAZ TECHNOLOGIES started in 1995
Staff of 5 Engineers
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Experience
Racing experience includes:
o Race driving
o Race engineering
o Chassis/Suspension
development
o Data acquisition and
analysis
o Suspension design,
analysis & fabrication
o Shock absorber
development
o 7-Post Testing
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KAZ TECHNOLOGIES
GM Racing
Other
Race engineering
Damper design & development
Damper sales & service
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Race Engineering
7-Post testing
Suspension engineering
Shock design, development & tuning
Vehicle tuning
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Jim Kasprzak-Automotive
31 years automotive experience
Arvin Ride Control
Director, Original Equipment Engineering
Director, New Product Development
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Course Outline
Damper Basics
Inside the Damper
Damper Testing
Damper Design
Advanced Tools
The Final Word
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Damper Basics
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A Shock is a DAMPER!
Dampens sprung and unsprung mass
Dissipates this energy into heat
Only produces force when in motion
Dampers are VELOCITY sensitive device
Force produced is proportional to velocity
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A Shock is a DAMPER!
Sprung Mass
(Chassis)
Spring
Damper
Unsprung Mass
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A Shock is a DAMPER!
The damper controls the suspension
In broad terms:
Rebound controls sprung mass
Compression controls unsprung mass
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Functions of a Damper
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Functions of a Damper
How do we use dampers on vehicles?
Primary Function
Dampen sprung & unsprung resonant frequencies
Secondary Function
Controls vehicle at pitch, heave and roll resonant
frequencies
Controls rate of weight transfer
Braking, corner entry, acceleration
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Functions of a Damper
At best, dampers are
The frosting on the cake
Dampens vibrations at resonant frequencies
Controls rate of weight transfer
Enhances vehicle performance
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Functions of a Damper
In worst case, dampers
Hold the cake together!
Compensates for structural deficiencies
Controls heave, pitch, roll imbalances
Used to compensate for deficiencies in design
or other components
Compensates for lack of suspension travel
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Resonant Frequencies
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Resonant Frequencies
A suspension is two
spring/mass/damper
systems in series
Sprung Mass
(Chassis)
Spring
Damper
Unsprung Mass
Suspension
Tire Spring
Tire Damping
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Resonant Frequencies
Sprung Mass
Unsprung Mass
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2.0 4 Hz
1 2 Hz
1.5 4 Hz
3 -5 Hz
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FSAE
Passenger Car
NASCAR Cup Car
Indy Car
22 - 26 Hz
10 - 12 Hz
15 - 17 Hz
23 - 27 Hz
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Critically Damped
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Passenger
Car
Non-Aero
Racecars
Critical
Damping
Aero Racecars
Ride: 0.7-1.1
Roll: 6.0-9.0
Milliken
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Gillespie
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To control resonances
To control pitch and roll rates
To control suspension travel
Minimize tire force variation
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Questions?
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This document is property of Kaz Technologies. Not authorized for use by outside organizations
Gas Pressure
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Gas Pressure
Purpose
Pressurizes oil in damper
Reduces hysteresis
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Gas Pressure
In Monotube
Balances the pressure in
compression chamber (P2)
Prevents cavitation or lag
High gas pressure typically required
Produces high friction and static rod
force
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Gas Pressure
In Monotube with Basevalve
Compensates for minor fluid loss
Pressurizes oil in damper
Balances pressure across base valve
P4 vs. P3
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Rebound Flow
Low Speed Rebound
Controls 0 2 in/sec damping
In valving
Bleed holes
By-pass jet
Leakage
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Rebound Flow
Mid Speed Rebound
Controls 2-8 in/sec damping
In valving
Disc preload
Disc stack
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Rebound Flow
High Speed Rebound
Controls > 8 in/sec damping
In valving
Piston ports
Restriction of disc stack travel
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Compression Flow
Low Speed Compression
Controls 0 2 in/sec damping
In valving
Bleed holes
By-pass jet
Leakage
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Compression Flow
Mid Speed Compression
Controls 2-8 in/sec damping
In valving
Disc preload
Disc stack
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Compression Flow
High Speed Compression
Controls > 8 in/sec damping
In valving
Piston ports
Restriction of disc stack travel
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Cavitation
What is Cavitation?
Negative pressure in rebound or compression
chamber
Creates void in chamber
Result is lag in force
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Cavitation
Compression Pressure
Rebound Pressure
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Cavitation
Cavitation
No Cavitation
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Cavitation
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Cavitation
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Cavitation
Hydraulic
Lag
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Cavitation
Red = 100 psi
Green = 75 psi
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Cavitation
Green = 75 psi
Red = 100 psi
Cavitation is not
always evident in
Force/Velocity
graph!
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Hysteresis
Red = Baseline
Green = Hysteresis
Hysteresis
Hysteresis is also
caused by
compression
pressure imbalance
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Questions?
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Damper Testing
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Or
Multiple speed
Peak force plot
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Force Velocity
Force Absolute Velocity
Compression Open, Rebound Closed
Rebound Open, Compression Closed
Force Displacement
PVP Peak Velocity Plot
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Force - Velocity
Compression
Rebound
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Rebound
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Rebound
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Rebound
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Force - Displacement
Compression
Rebound
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Compression
Curve connects
Individual points
Rebound
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Rebound
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This document is property of Kaz Technologies. Not authorized for use by outside organizations
This document is property of Kaz Technologies. Not authorized for use by outside organizations
This document is property of Kaz Technologies. Not authorized for use by outside organizations
This document is property of Kaz Technologies. Not authorized for use by outside organizations
This document is property of Kaz Technologies. Not authorized for use by outside organizations
This document is property of Kaz Technologies Not authorized for use by outside organizations
No lags
No signs of cavitation
No incongruities
Minimal hysteresis
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Hydraulic Lag
Hydraulic
Lag
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No Cavitation
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Minor Cavitation
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Slight Cavitation
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Cavitation
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Massive Cavitation
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Incongruity
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Hysteresis
Hysteresis
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Proper Curve
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Compression Open
Rebound Open
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Force Displacement
Compression Open
Rebound Open
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Questions?
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Damper Design
Damper architecture
Adjusters
Design process
Tuning process
Tuning guides
Damper care & feeding
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Damper Architecture
Twin tube
Monotube
Monotube with basevalve
Twin tube with piggyback reservoir
Monotube with remore reservoir
Monotube with piggyback reservior
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Damper Architecture
Choose the design that serves the application
Function
Packaging
Performance
Price
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Twin Tube
Primarily used in OE applications
Inexpensive
Has to be mounted rod up
Valving in piston and base valve
Typically smaller piston OD than
monotube
No separation between oil & gas
Pressure balance required
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Monotube
Compression & rebound valving
in piston
No base valve
Typically high gas pressure
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This document is property of Kaz Technologies. Not authorized for use by outside organizations
This document is property of Kaz Technologies. Not authorized for use by outside organizations
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Adjusters
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Adjusters
Various types of adjusters
Rebound
Compression
Rebound & compression
High speed compression & rebound
Low speed compression & rebound
Adjusters
Multiple adjusters interact
High speed and low speed adjusters interact
They are not totally independent
The setting of one adjuster will often determine the
effectiveness of the other adjuster
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This document is property of Kaz Technologies. Not authorized for use by outside organizations
This document is property of Kaz Technologies. Not authorized for use by outside organizations
Adjusters
Single Adjusters
Typically rebound in rod
Typically compression in reservoir
Can adjust low speed, high speed or both
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Damper architecture
Damper features
Packaging on vehicle
Dimensions
Performance characteristics
Initial damping characteristics
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Damper Architecture
Choose the architecture that serves the
application
Function
Packaging
Performance
Price
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Damper Features
Choose the features that serve your application
Piston diameter
Number and type of adjustments
Piston and valving design
Base valve design
Jounce bumper?
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Packaging on Vehicle
Mountings
Travel or stroke
Is the damper a travel limiter?
Coil-over spring travel on shock
Jounce bumper travel
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Dimensions
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Performance Characteristics
Damping requirements
Damping adjustment ranges
Spring rates and travels
Jounce bumper engagement point, rate
and travel
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Tuning Process
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Tuning Process
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Transistions
Braking, turn-in, acceleration
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Advanced Tuning
More than basic tuning
Track testing
Transition maneuvers
7-post testing
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Tuning Considerations
A damper is a VELOCITY sensitive device
Force is a function of velocity, not
displacement
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Tuning Considerations
Velocity for transients typically
below 2 in/sec
Turn-in
Braking
Acceleration
Aero control
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Tuning Considerations
Velocities for bumps typically 2-10 in/sec
Velocities for extreme travel events above
10 in/sec
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Tuning Guides
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Tuning Guides
There are many ways to use dampers
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Questions?
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Advance Tools
Damper testing
7-post testing
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Damper Testing
Multi-Frequency Testing
Variable frequency and amplitude sine sweep
Actual vehicle data
Actual data
Low frequency (sprung resonance) data
High frequency (unsprung resonance) data
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Damper Testing
Roehrig EMA Dyno
Electro-magnetic actuator
Triangle, sine, square and
composite waves
Can play back shock
displacement data from track
data
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Damper Testing
Multiple Input Test
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Track
Data
Low
Freq
Track
Data
High
Freq
Track
Data
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7-Post Testing
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What is a 7-post?
The 7-post shaker is an engineering system
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What is a 7-post?
Four wheel pan actuators
Same load throughout the test (except when active aero is in use)
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7-Post Testing
7-Post Drive Inputs
Sine sweep
Track data based drive file
Discreet event
Low frequency from track data
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This document is property of Kaz Technologies. Not authorized for use by outside organizations
This document is property of Kaz Technologies. Not authorized for use by outside organizations
This document is property of Kaz Technologies. Not authorized for use by outside organizations
This document is property of Kaz Technologies. Not authorized for use by outside organizations
Data Processing
Results Workbook
Customized Team Results and Reports
Graphical Plotting & Analysis Tool
Team Console
Drive File Quality
7-Post Performance
Load Transformation
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Questions?
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Records
If you dont keep records, you start from
scratch every time you start the car!
You can only improve if you know where you
are starting from!
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Records
Setup Sheets
Run Log
Driver Evaluation Sheets
Race/Test Summary
Track Data Files
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Setup Sheets
Baseline or starting setup
Shop setup
Final setup at track
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Event Information
Chassis Information
Packer Gap
Aero Information
Gearbox Information
Session Tabs
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Run Log
EXCEL File with Worksheets for:
Race/Test Summary
Worksheet for each session
Data Analysis Summary
Tire Summary
Race Log
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Opening Page:
Event Summary
Tabs for:
-Summary
-Data Analysis
-Tire Sheet
-Session Sheets
-Race Log
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Session Information
Tire Data
Tire Info
Driver Comments
Changes
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Tire Sheet
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Race Information
Lap Times
&
Leader Info
Driver Comments
Tire Data
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Event Information
Weekend Summary
Race Summary
Driver De-Briefs
Next Race
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EVERYTING is a compromise!
You dont have to have it all perfect to win
In fact, you wont get all of it right!
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References
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References
Books by Carroll Smith
Tune to Win
Drive to Win
Prepare to Win
Engineer to Win
Nuts, Bolts, Fasteners and Plumbing Handbook
Engineer In Your Pocket
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References
Books
Race Car Vehicle Dynamics
William F. Milliken and Douglas L. Milliken
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Kaz Technologies
http://www.kaztechnologies.com
Information about Kaz Technologies
Product information
FSAE damper drawings, CAD and damping info
Tech Tips
Seminar downloads
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Kaz Technologies
Questions?
FSAE_Shock@kaztechnologies.com
Topics to Discuss?
http://www.facebook.com/Kaz.Technologies
Start a discussion!
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Kaz Technologies
Jim Kasprzak
jkaz@kaztechnologies.com 248855-3355
Tom Jaworski
tjaworski@kaztechnologies.com
734-536-3218
Jess Youngblood
jess@kaztechnologies.com
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Kaz Technologies
http://www.facebook.com/Kaz.Tech
nologies
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Thanks!
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