MUHAMMAD AYUB

(BSME 01113148)
MANUFACTURING PROCESSES-2
MANUFACTURING OF
SHOCK ABSORBER
WHAT IS SHOCK ABSORBER.....??
shock absorber, also called Snobbier, device for controlling
unwanted motion of a spring-mounted vehicle. On an automobile,
for example, the springs act as a cushion between the axles and
the body and reduce the shocks on the body produced by a rough
road surface. Some combinations of road surface and car speed
may result in excessive up-and-down motion of the car body.
Shock absorbers slow down and reduce the magnitude of these
vibratory motions.
RAW MATERIAL
Steel..
Stainless steel and other steel grades are used to manufactured the
shock absorber.
PROCESS
Cutting
Forming
Welding
Compaction and Sintering
Assembling
I. Welding
II. Oil pouring
III. Gas insertion
Cleaning
Painting

CUTTING
It involves dissecting or dividing a sheet of raw material into
equivalent circumference of respected geometry or part.
Sheet metal is cut into various strips that go on to become
cylinder.
FORMING
Now the material strips are passed through a set of rollers that are
set upon various angles, that forms a round cylindrical pipe of the
strips. These pipes are than cut into various required lengths.
WELDING
The newly formed pipe is than fusion welded at the groove that is
formed due to forming when both ends of the sheets join together. A
copper welding wheel is used for this purpose.
COMPACTION and SINTERING
In a separate process metallic powder is compacted and thus
formed into a cap shaped part that would seal the ends of cylinders.
These compacted caps are than sintered so that their strength is
increased.
ASSEMBLING
Assembling process involves various steps that would include
welding, joining, finishing and inspecting.
First of all the cylinder and the cap or stopper is welded
together then shock absorbing oil is added to the cylinder in which
the piston would move. Now both piston and cylinder part are
joined together.

This finished shock absorber is than checked for leaks. Nitrogen gas
is added to the cavity containing oil in order to stop oil from
forming. Nitrogen is added by a puncher and than that puncher is
spot welded.
Diagrams

CLEANING
Shock absorber is than finished and prepared for the painting
process by getting washed thoroughly and removing oil.
PAINTING
Shock absorber like many other metal products are painted using
electrostatic process. This involves giving the shock absorber and
paint opposite charges. So that the paint would readily adhere to its
surface and prevent it from corrosion.