Design Optimization of Jounce Bumper Support Ring Based on RWUP Loading

Designing and manufacturing a support ring (POM ring -Polyoxymethylene ring) for a MacPherson strut suspension system brings unique set of challenges due to the high-performance and durability demands for Indian road application. Support ring along with the jounce bumper used in the shock absorber is designed to absorb the strong shock coming from the road inputs when suspension travel reached to the maximum limit. thereby absorbing the impact energy and preventing it from transferring it to the body. A bump stopper for a suspension of a vehicle is made of poly urethane (PU) material and is surrounded by a support ring or POM ring made up of Polyoxymethylene material. The bump stopper deflects into bellow shape during the absorption of impact energy. In the present paper, the authors have demonstrated the key challenges experienced in successfully designing the support ring post initial failure experienced in the validation phase which was unprecedented. The authors detail the failure analysis and the subsequent design improvement in the present work.