DEPARTMENT OF MECHANICAL ENGINEERING

MINOR PROJECT
DESIGN AND ANALYSIS OF SHOCK ABSORBING LIQUID

Bachelor of Technology
In
Mechanical Engineering

Maulana Azad National Institute of Technology, Bhopal

PREPARED BY (BATCH-4):

GUIDED BY:

VIVEK KUMAR 131116210

DR. ALOK SINGH

CHANDRASHEKHAR SAHU- 131116212

KISHAN SAHU-131116301
SUMIT CHOUBEY-131116225

SALi

Declaration

We hereby declare that the project entitled DESIGN AND ANALYSIS OF

SHOCK ABSORBING LIQUID as our Minor project during the session
January2016-April2016 has been completed successfully under
the expertise guidance of Dr. Alok Singh, Department of
Mechanical Engineering and this project is submitted in the partial
fulfillment of the requirement for the award of Bachelor of
technology in Mechanical Engineering.

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Acknowledgement

For the completion of this project we would like to show my sincere gratitude to our
faculty advisor Mr. Alok Singh, Department of Mechanical Engineering under whose
expertise guidance we are able to complete our project successfully. Design and
analysis of Shock absorbing Liquid (SALi) is certainly a new task for us that wouldnt
be possible without helpful support and precise guidance regarding the project.
We are also thankful for our Department for providing required facilities for
the successful completion for this project.

CONTENTS

1. Introduction.page 5
1.1 Expanded polystyrene...page 8
1.2 Viscous matrix fluid.page 10
2. Literature Survey..page 12
3. Objective...page 14
4. Test performed..page 14
5. Results..page 16
6. Applications. page 19
7. Conclusion..page 25
8. Bibliographypage 26

Page 3

Page 4

1. INTRODUCTION
The Shock absorbing specimen is a composite material designed to absorb the energy
of impacts, vibrations and shock waves. It consists of a large number of small
elastomeric capsules surrounded by an incompressible matrix liquid retained in a
Flexible low stretch packaging. Many different materials can be used to make Shock
absorbing specimen. The small capsules may be closed or open gas filled capsules,
expanded polystyrene beads or polymeric microspheres for example. For the matrix
fluid, any liquid which can hydraulically transfer pressure changes is potentially
usable. The size and the shape of the container affect the impact energy absorbing
Performance. The container must be leak proof and deform easily under impact but
not stretch significantly. This is to enable the capsules under and adjacent to the
impact zone to rearrange themselves in the package whose front face takes the shape
of the impactor. It consist of lots of small, compressible elastic capsules blended with
an incompressible matrix fluid, with the mixture being retained in a strong
package, which does not stretch significantly during an impact.
Shock absorber specimen cushions offer four damage mitigation mechanisms:
1. The capsules absorb energy when they suffer bulk compression during an
impact.
2. Viscous damping converts impact energy into heat when the matrix fluid swirls
round the compressing capsules. This reduces the kickback when the
capsules spring back into shape in the milliseconds following the impact.
The hydraulic characteristics of the matrix fluid distribute.
3. Shock waves are scattered at the capsule fluid interfaces.

PACKAGING

Shock absorbing specimen

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The packaging used for the published research varies from stout cotton bags to piston
and cylinder arrangements. A key feature of the SAS concept is that stretching of the
packaging must be minimized in order to maximize the capsule compression and
viscous damping processes. In principle, the shear thickening gel versions of that lock
up under impact don't require a low stretch packaging. But unpackaged gel SAS is less
effective than the original packaged version.
Basic Shock absorbing specimen Mechanism:

During an impact the capsules shrink in size as they are compressed on all sides by the matrix
fluid. The capsules, lubricated by the fluid, rearrange themselves inside the package, so that
the front face of the package takes up the shape of the impacting body

The matrix fluid in principle any liquid or gel which allows the hydraulic transfer of
pressure can be used as the matrix fluid. In experiments silicone oil, glycol
antifreeze, wallpaper paste, Vaseline, mastic sealant and a range of engineering
greases have been used as the matrix fluid. In order to maximize viscous damping very
Thick liquids having a viscosity similar to treacle are preferred. Gooey mastics or
silicone gels are good because there are no leakage problems if the packaging is
damaged. Shear thickening fluids allow the package to change shape easily when
Deformed slowly, but stiffen up during violent impacts. This feature is appealing in
protective clothing, for example in pads to protect the spinal column of motorbike or
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equestrian riders. The capsules Elastomeric capsules include hollow rubber balls,
expanded polystyrene beads, polymeric microspheres, bubbles cut from bubble
packing and narrow diameter, open ended, hollow tubes, with filaments of air trapped
inside them. The inclusion of hollow glass microspheres has been proposed as a
mechanism for adding shear thickening.
The packaging If the packaging stretches significantly during an impact then some
impact energy is absorbed but overall, energy absorbing efficiency is reduced because
the capsules suffer less compression and the matrix fluid provides less viscous
damping.

Reducing the weight of shock absorbing Specimen:

The matrix fluid is responsible for most of the weight of SAS based devices. So the key
to weight reduction is to minimize the fluid fraction by close packing the capsules.
Spherical elastomeric capsules: The basic SAS formulation as illustrated in has a
single size range of low density capsules, with the matrix fluid occupying about 34% of
the volume. The fluid fraction can be reduced by using two size ranges of capsules,
with small capsules occupying part of the void spaces between the larger capsules.
This reduces the matrix fluid to about 12% of the volume.
The larger capsules could be expanded polystyrene beads and the smaller ones,
polymeric microspheres. The matrix fluid fraction can be further reduced by
introducing hollow nanoparticles between microspheres.
Of the smallest size of capsules are fairly rigid, compared with the larger ones, the
smaller capsules will tend to bunch up during impact, producing a shear thickening
effect.

Maximizing the viscous damping for a given mass of Shock absorbing specimen:

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In order to maximize viscous damping during an impact the shear movements between
adjacent elements of matrix liquid should be maximized.
The general rule for doing this is:
The larger the elastomeric capsule, the lower the bulk compressive stiffness should
be. For example, in the case of 23 Centimeter sided cube based SAS, with the pure
liquid mass minimized by adding polystyrene beads and polymeric microspheres.

1.1 EXPANDED POLYSTERIN

Expanded Polystyrene (EPS) is a rigid cellular plastic, which is found in a multitude of
shapes and applications. It is used for fish boxes, packaging for electrical consumer
goods and for insulation panels for building. These are the most commonly known uses
and we will mention others in this document. XPS (extruded polystyrene) is also
plastic foam based on polystyrene that is formed by adding gas during extrusion not
by expanding beads containing gas; which is how EPS is formed. A well-known use of
XPS is the vac-formed polystyrene trays used for small portions of food that we see in
the supermarket. The extruded polystyrene foam is a fine laminate that is only 2-3
mm thick.

Raw Material: Expanded polystyrene is made from expandable polystyrene, which

is a rigid cellular plastic containing an expansion agent.EPS is obtained from
oil
Entire Manufacturing process that lead us to EPS (Expanded polystyrene
beads).

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1st stage

2nd stage

3rd stage

Pre-expansion

Intermediate Maturing and

Expansion and Final

Stabilization

Moulding

The raw material is heated

On

cooling,

in special machines called

expanded

the

particles

recently

During

from

stabilized pre-expanded beads

pre-expanders with steam at vacuum in their interior and this

must be compensated for by air
temperatures of between

are

this

stage,

transported

where

they

to

moulds

are

again

80-100C. The density of the

diffusion. This process is carried

subjected to steam

material falls from some

out during the materials

So

630kg/m3 to values of
Between 10 and 35kg/m3.
During this process of preexpansion the raw materials
compact beads turn into
cellular plastic beads
with small closed cells that
hold air in

Intermediate

maturing

that

the

the

beads

bind

in

together. In this way moulded

aerated silos. The beads are

shapes or large blocks are

dried at the same time. This is

obtained(that

how the beads achieve greater

sectioned to the

mechanical

required shape like boards,

elasticity

and

improve expansion
Capacity very important in
the

following

transformation

stage.

Their interior.

Expanded Polystyrene beads

Page 9

are

Panels, cylinders etc).

later

1.2 Viscous matrix Fluids

These are the viscous fluids which can be used to prepare shock absorbing
specimen
1. Grease
2. Glycerin
Grease:- Grease is a semi solid lubricant which generally

consists of a soap

emulsified with mineral or vegetable oil. The characteristic feature of greases is that
they possess a high initial viscosity, which upon the application of shear, drops to give
the effect of an oil-lubricated bearing of approximately the same viscosity as the base
oil used in the grease. This change in viscosity is called shear thinning.
Grease is sometimes used to describe lubricating materials that are simply soft solids
or high viscosity liquids, but these materials do not exhibit the shear-thinning
properties characteristic of the classical grease. For example, petroleum jellies such
as Vaseline are not generally classified as greases. Greases are applied to mechanisms
that can only be lubricated infrequently and where lubricating oil would not stay in
position. They also act as sealants to prevent ingress of water and incompressible
materials. Grease-lubricated bearings have greater frictional characteristics due to
their high viscosity.
Grease having the properties which consists of oil or other fluid lubricant that is
mixed with a thickener, typically a soap, to form a solid or semisolid. Greases are a
type of shear-thinning or pseudo -plastic fluid, which means that the viscosity of the
fluid is reduced under shear. After sufficient force to shear the grease has been
applied, the viscosity drops and approaches that of the base lubricant, such as the
mineral oil. This sudden drop in shear force means that grease is considered a plastic
fluid and the reduction of shear force with time makes it thixotropic. It is often
applied using a grease gun, which applies the grease to the part being lubricated
under pressure, forcing the solid grease into the spaces in the part.

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Glycerin: - It is a simple polyol (sugar alcohol) compound. It is a colorless,

odorless, viscous liquid that is sweet-tasting and non-toxic. It is widely used in the
food industry as a sweetener and humectants and in pharmaceutical formulations.
Glycerol has three hydroxyl groups that are responsible for its solubility in water and
its hygroscopic nature. The glycerol backbone is central to all lipids known
as triglycerides.

Shock
A mechanical or physical shock is a sudden acceleration caused, for example, by
impact, drop, kick, earthquake, or explosion. Shock is a transient physical excitation.
Shock describes matter subject to extreme rates of force with respect to time. Shock
is a vector that has units of acceleration (rate of change of velocity). The unit g (or g)
represents multiples of the acceleration of gravity and is conventionally used.
A shock pulse can be characterized by its peak acceleration, the duration, and the
shape of the shock pulse (half sine, triangular, trapezoidal, etc.). The Shock response
spectrum is a method for further evaluating a mechanical shock

Shocks are usually measured by acceleratometers but other transducers and high
speed imaging are also used. A wide variety of laboratory instrumentation is available.
Field shocks are highly variable and often have very uneven shapes. Even laboratory
controlled shocks often have uneven shapes and include short duration spikes; Noise
can be reduced by appropriate digital or analog filtering.
Governing test methods and specifications provide detail about the conduct of shock
tests. Proper placement of measuring instruments is critical. Fragile items and

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packaged goods respond with variation to uniform laboratory shocks. Replicate testing
is often called for.

2. Literature Survey

1. SALi Technology was invented in Britain 29 years ago.

2. SALi based cushions have been proposed for protecting people and property
from violent impacts, vibrations and shock waves. They were first described by
Bill Courtney in the 1990s.
3. Depending on the market requirements, design issues that can be solved by
SALi based designs include low weight, soft feel, flexibility for articulated parts
of the body, penetration resistance and temperature control. Where flexibility
is important packaging based on strong poly-cotton, Kevlar or Cuban fibre can
be used.
4. In 2003, the market leading product was a plastic Hip Shield. This was inserted
into the underwear and covered the hip bone area. It looked similar to a
footballer's shin pad but included a cushioning layer of elastomeric foam. A
Manchester undergraduate student carried out tests in which he replaced the
foam with SALi. The reduction in maximum force experienced during impact
was significant.
5. Unfortunately academic jealousy problems at Manchester University resulted in
the funding bid being abandoned in late 2003.
6. Work by Valentin LeRoy at Paris Diderot University, France suggests that SALi
type materials may employ a process known as Minnaert scattering to reduce
sound transmission through walls
7. LeRoy's work is in line with earlier unpublished SALi research carried out at
Cranfield University Royal Military College of Science. Researchers under the
supervision of Professor Horsfall have verified that SALi type materials have
good blast wave mitigation properties.
8. Impact tests can be very expensive, with the test piece commonly being
destroyed during the impact. To minimise costs, engineers need to have a good
idea of the outcome before an impact test take place.In recent years the key
to cost reduction has been to carry out a range of computer simulated impact
tests, before carrying out a live test on the most promising design.
9. One more problem is that the text book techniques used for measuring the
core characteristic properties of solid and foam based impact absorbers cannot
be applied to SALi because of its novel, visco-elastic fluid nature. The limited
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number of SALi characteristics that have been published to date cannot be used
in computer simulations because they fail to reflect SALis complexity.
10.Other early investigations in Britain failed because they used inappropriate
materials, such as elastic packaging and corrosive fluids which damaged the
packaging. Consequently, in spite of 300,000 research funding by the British
Government, commercial interest declined after 2003
11.More recent work in China and Britain has been far more successful. For
example, after completing their study of a SALi based vibration isolator,
researchers at Nanjing University concluded that it, offers outstanding
performance and a good prospect in engineering practice
12.In 1986 Bill Courtney decided to celebrate his fortieth birthday by riding one of
the recently invented mountain bikes from Lands End to John OGroats. The
bulk of the journey was off-road. His cycling mitts offered limited protection
against the vibrations caused by riding over rough ground and he suffered
several injuries because he was not wearing a helmet any protective clothing.
In those days, there was very little protective cycling gear on the market.
13.In 1997,A two page article in Eureka magazine describes Bill's proposals for
using SALi in car bumpers. It attracts interest from the BBC, but annoys his
supervisor.
14.Bill changed the name of his invention to "Manchester Material" in an attempt
to appease his Manchester University research supervisor. But it had the
opposite effect, so he reverted to its original name, Shock Absorbing Liquid
(SALi).
15.In 1998,22nd October, BBC Radio 4 broadcast a documentary programme,
"Science in the Attic" exclusively featuring Bill Courtney as an inventor. As a
result of the programme, Bill is invited to discuss SALi Technology with
engineers at the Motor Industry Research Association (MIRA) laboratories in the
Midlands.
16.Presently number of researchers is working on regenerative shock absorber.
17.Industries are using SALi based isolators.
18.SALi based suspension units were invented in Britain by Bill Courtney, but their
technical development is being led by china.
19.SALi is having great importance but only few countries are aware of its
importance.
20.India should have begin research on this technology in order gain light weight,
cost effective means to control danger regarding safety and vibration and SALi
technology is a great option in this regard.
21.SALi future scope and its application are as follows: SALi HAT, Bumper System,
car suspension system, vibration control, pedestrian protection, flooring of car
and wartime mitigation.

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3. OBJECTIVE:
To design, analyze and simulate shock absorbing liquid (SALI) based specimen with its
application in daily life

4. Test Performed:Many formulations are possible for a Shock absorber specimen based impact absorber.
The combination of materials and mixture proportions with the right elastic and
viscous damping properties have to be found to solve the impact absorbing problems
of pedestrian protection. The shock absorber should minimize acceleration and
displacement during impacts with pedestrians as well as with other vehicles or street
furniture. The weight, thickness and cost of the SAS filled bumper must also be at the
minimum.
COMPOSITION: The formulation of Shock absorbing specimen consists of
elastomeric beads and a viscous matrix fluid. Two types of beads were used for the
preparation of the Shock absorbing specimen: expanded polystyrene beads (diameter:
4-7mm) or polymeric microspheres (diameter: 60-90m). The blending of the two
Consists of parts by volume.
EPS BEADS
66%

MATRIX FLUID
34%

In order to reduce weight of specimen we can introduce polymeric microsphere in voids

of EPS beads
EPS BEADS
66%

Polymeric
Microsphere
22.5%

Matrix fluid
11.5%

We have designed a specimen on CATIA designing software and performed stress test
on it. For analysis as the specimen is composed of two material namely expanded
polystyrene and viscous matrix fluid so there property has been assigned to it. Initially
we have designed a specimen whose width is 50mm and performed impact test on it
by applying load by impactor having weight of 5kg. On it and thereby getting graphs
between impact velocity and load applied. Similar, test has been performed on
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specimen having width of 70mm and 150mm of width and thereby getting result
considerably.

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Force against deflection was recorded from each of the tests.

The efficiency was investigated using the following
Relationship:
F(x)dx = Fx
Where:
F = Peak Force
x = Deflection
= Waveform efficiency

5. Results
Influence of Shock Absorber Length
The initial series of tests investigated change in absorber length upon peak load and
absorber efficiency. The peak load for each of the test results is compared against
change in velocity and in efficiency the impact conditions were the same for each of
the samples; the only change was the length of the pad perpendicular to the
longitudinal axis of the impactor.
Fixed Parameters
- Impactor mass: 5.2 kg
- Striker shape: cylinder (25mm diameter)
- Package: polythene tubing
- Sample cross sectional area: 70x50mm
- Fluid viscosity: 1000cSt
- Capsules: EPS beads
Variable Parameters
- Impact velocity: 0.8-2.4m/s
- Sample length: 70-320mm

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Maximum load vs impact velocity

Efficiency vs impact velocity

Influence of viscosity
The second series of tests investigated changes in viscosity of the matrix fluid. The
experimental setup from test series one was replicated. The change was that the
sample length was a fixed parameter and the fluid viscosity was a variable parameter.
The choice of sample length was based on assessment of test series 1 result.
Fixed Parameters
- Impactor mass: 5.2 kg
- Striker shape: cylinder (25mm diameter)
- Package: polythene tubing
- Sample crosses sectional area: 70x50mm
- Capsules: EPS beads
- Sample length: 170mm
Variable Parameters
- Impact velocity: 0.8-2.4m/s
- Fluid viscosity: 100cSt, 1000cSt and 12500cSt

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Maximum load vs impact velocity

Efficiency vs impact velocity

Page 18

6. Application and Future in Mechanical Engineering

Battery charging car suspension

Motor vehicle suspension units provide passengers with a smooth, stable ride and
make the steering easier to handle. Each unit has two components: a spring and a
damper.

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The springs are compressed as the wheels travel over bumps. Then, as the springs
expand, the dampers absorb energy, to prevent the vehicle bobbing up and down.

This damper action produces waste heat that has to be dissipated into the
environment. Up to 5% of the vehicle fuel is used up by damper action, with the
percentage increasing with vehicle size.
Our Shock absorbing specimen suspension design is different. It converts energy
mopped up by the dampers into electricity instead of wasting it. The electricity can
be fed back into the battery, increasing the range of battery powered vehicles.

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A Shock absorbing specimen based suspension system that can generate electricity.

2.

The basic Shock absorbing suspension unit

The basic SAS suspension design integrates the spring and damper functions.

The elastomeric capsules (for example foam rubber or hollow rubber balls) can be
compressed like springs. As the capsules change in size internal friction produces
some damping. Additional damping is produced as the hydraulic fluid swirls round the
shrinking/expanding capsules.
3.

Adding extra damping on the expansion stroke (Conventional design.)

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The empty suspension unit.

The viscous damping grid can move up and down to act as a valve .

Hydraulic fluid can pass round the rim of the damping grid on the compression stroke, but is
forced through holes in the grid on the expansion stroke.

Benefits of the conventional Shock absorbing specimen suspension design:

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 It does not require any precision made parts to be manufactured, so production

costs are low.
Light in weight.
The simple design reduces recycling costs at the end of the products working
life.

FINE TUNING THE SUSPENSION PERFORMANCE

The design offers simple methods for altering the suspension stiffness and damping

IMPACT ATTENUTOR
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Improving the crash protection offered by vehicle box sections.

The matrix liquid transmits pressure, offering energy adsorption by compression inside the whole length of the box
section.

To minimize the liquid weight, three sizes of compressible capsule can be

used:
1 large
aluminum
foam
balls
fill
most
of
the
volume.
2 Expanded polystyrene beads fit into the spaces between the Al balls.
3 Polymeric micro-spheres fit in the spaces between the polystyrene beads.

Vibration isolation units (vehicle suspension systems)

Several SAS based designs have been proposed. A common characteristic is that the
elastomeric capsules stiffen up as they are compressed. This allows the suspension
unit to offer a soft ride when travelling over smooth roads, then automatically
stiffening up when moving over rough ground. Here is one of the proposed designs:

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Page 25

7. CONCLUSION

Shock Absorbing Liquid, SALi offers engineers a new approach to impact, vibration and
blast protection. It has the potential to solve many human body protection problems,
transport safety and blast mitigation problems. SALi consists of lots of small
elastomeric capsules like expanded polystyrene beads, and mixed with a matrix liquid
or grease.
When suitably packaged, SALi offers a novel combination of impact absorbing
characteristics. Its elastic, like elastomeric foam provides good viscous damping, like
a suspension damper. It also has hydraulic load spreading properties. This allows SALi
based body armor to spread impact loads over a greater area of underlying body
tissue, compared with elastomeric foam based body armor. SALi pads in clothing &
helmets are more flexible and cooler than foams of equivalent stiffness.
SALI based devices are due to its regenerative application in damping system,
vibration control, and low cost, easy availability can come forth with its application in
economic world and importance in day to today life. Working on this project is our
initiation in this technology which can provide serious effect in field of Engineering
related

to

safety,

comfort

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and

wartime

mitigation.

8. BIBLIOGRAPHY

BOOKS

B.C. PUNAMIYA-STRENGHT OF MATERIAL

WILLIAM CALLISTER-MATERIAL SCIENCE

RESOURCES

Courtney, W. A. Preliminary investigations into the mechanical properties and

potential applications of a novel shock absorbing liquid, MPhil Thesis,
Manchester School of Engineering, University of Manchester (1998).

Courtney W A and Oyadiji S O (2001). Preliminary investigations into the

mechanical properties of a novel shock absorbing elastomeric composite.
Journal of Materials Processing Technology 119 (2001) 379-386.

G. Georgiades et. al., University of Manchester, Characterization of the Core

Properties of a Shock Absorbing Composite, Journal of Engineering Materials
and Technology, ASME, October 2007, Vol. 129, pages 497-504.

H. d. Teng, Q. Chen, Study on vibration isolation properties of solid and liquid

mixture, Journal of Sound and Vibration, (2009) doi.10.1016/j.jsv.2009.04.036

WEBSITES
www.google.com
www.youtube.com
www.wikipedia.com

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