Calculations
Calculations
ISSN: 2319-7064
SJIF (2022): 7.942
Abstract: As an enthusiastic FSAE team, our objective is to design the most effective Suspension system for a Formula student race
car. In this paper, we presented in detail the design procedure of the double wishbone pushrod suspension system, mechanical
properties of the materials used, analytical calculations, determination of suspension hard points in CATIA V5, graphical analysis are
examined for dynamic simulation of suspension system in Lotus Shark. The CAD models of the components in the suspension system
are made using SolidWorks® and the Finite element analysis of the components is done using ANSYS® Workbench.
Keywords: Double wishbone; Pushrod; Material selection; Suspension Points in CATIA V5; Dynamic Simulation Analysis of
Suspension System in Lotus Shark
We designed our race car in such a way that forces that the 2. Material Selection
tires absorb are transferred to the Upright. From the Upright,
the forces are then made to transfer to the pushrod and the 2.1 Uprights
control arms. The pushrod then forces the Bell crank to
move accordingly and then bears the forces on the damper. Our uprights are made of Al 6061 T6. Most common
The damper absorbs most of the forces and the remaining material used for Uprights is Aluminium. Al is used because
forces are transferred to the chassis. This system reduces the of its properties like low weight density, resistance to
shocks and any impact on the driver. This paper discusses corrosion and rusting etc. For manufacturing knuckle,
the kinematics design of a double a-arm Pushrod Suspension Aluminium is the best choice as it has enough load with
system for an FSAE Vehicle. standing ability. In Aluminium, we have different grades like
Al-6061, Al-5056, Al-7075, Al-6063 etc. Among these two,
The hardpoint‟s location can be determined using this Al-7075 and Al-6061 are most common used.
procedure to simulate motion in any kinematic simulation
software. Here, Lotus Shark is used as kinematic simulation However, Al-6061 is finalized for uprights. Al-6061 is
software, and the results are verified using Analytical chosen because:
Calculations. The obtained values are expressed as graphs to 1) Its hardness is within the desirable range (Brinell
visually understand the relationship between suspension Hardness no. = 95). The lower hardness allows it to be
parameters and vehicle performance. The process of iterative machined more easily than 7075 (BHN = 150).
Volume 11 Issue 11, November 2022
www.ijsr.net
Licensed Under Creative Commons Attribution CC BY
Paper ID: SR221108085737 DOI: 10.21275/SR221108085737 573
International Journal of Science and Research (IJSR)
ISSN: 2319-7064
SJIF (2022): 7.942
2) Easily machinable when compared to Al-7075 T6 11) Processing performance of Al-6061 is better than Al-
3) Although Yield strength of Al-6061 (276 MPa) < Al- 7075 and other grades.
7075 (510 MPa), we choose Al-6061 because stress 12) When dealing with fabrication, 6061 aluminium alloy
developed due to action of loads is not more than 270 has the edge over 7075 aluminium alloy.
MPa. Thus, Al-6061 can be used.
4) It has better structural strength compared to Al-7075. Keeping all these parameters in consideration, Al-6061 is the
5) It is tougher than many other materials including Al- best choice. If at all Hardness is not meeting the
7075 expectations, hardness can be improved by heat treatment
6) It has got better surface finish & corrosion resistance methods like Tempering. It is frequently used in automotive
when compared to Al-7075 & Al-6082. parts. Aluminium 6061 is a better alloy when the product is
7) It‟s Density is 2700 Kg/m3and low when compared to going to be welded or formed.
Al-7075 (2810 Kg/m3). Thus, for given volume, mass
consumption is less in the case of Al-6061. This reduces 2.2 Upright Height
overall weight and thus also expenses.
8) Material cost of Al-6061 (₹ 275/kg) is also less than Al - To decide upright height several factors were considered.
7075 (₹ 600/kg) & Al-6082 (₹ 335/kg) - thus Firstly, ICR‟s of both A-Arms and the line joining center of
economical. wheel to ICR to get Roll Centre Height were drawn. By
9) It has a high strength-to-weight ratio. Keeping Lower A-Arm Horizontal to get more stability and
10) It has high fatigue strength when compared to other adjusting upper A-Arm we decided to keep Upright's overall
grades and alloys. Although Al-7075 has more fatigue height as 200 mm with eye-to-eye length of 168 mm.
strength (159 MPa), Al-6061 is opted because fatigue Distance from uprights center to Upper ball joint = 84mm
strength of Al-6061 (58-110 MPa) is sufficient for our and upright center to lower ball joint = 84mm
requirements
2.3 Bell Crank traces of Cu, Ni, Mo, Cr-thus bridging gap between ductility,
strength, and toughness.
Material selected for Bell crank is Mild steel EN
1.0301. Although Mild steel is relatively inexpensive when Steel is prone to oxidizing if not prepared accordingly,
compared to other materials like Al 6061, Al 7075.It resulting in rust that damages (and eventually destroys) the
satisfies our requirements and there is no need to steel. Without the addition of any additional elements, mild
compromise in mechanical properties. Hardness of mild steel steel will suffer the same fate. Chromium is a popular
is 130 BHN. The hardness is enough to withstand addition to low carbon steel due to its reaction to exposure to
indentations and at the same time it is not too high so that it the atmosphere, resulting in a layer of chromium oxide that
is machinable. It has good weldability. Mild steel contains protects the steel underneath from further corrosion.The
roughly 0.05-0.30% carbon making it flexible. Mild steel has density of EN 1.0301 grade mild steel is 7850 kg/m³ which
a relatively low tensile strength 440 N/mm² when compared is quite acceptable. Having high tensile strength of 350-640
to other materials like Al 7075(572 N/mm²), However, it is MPa, Ultimate yield strength of 370 MPa, Shear stress of
enough to withstand the stresses and forces acting on bell 200-300 MPa; Mild steel is a better choice. Max Force
cranks. Hardness can be increased and improved by methods which is applied on our bell crank is 420.29N at Front and
like carburizing (Case hardening). Mild steel is ductile 466.95 N at Rear. So, our selection is perfect, and it can
enough to withstand forces acting on it. EN 1.0301 carbon withstand heavy loads at cornering without deflection.
steel contains 0.1% C+0.4% Mn+ 0.4% Si. It also contains
Rear wishbone lengths Front Wishbone lengths Front A-Arm Rear A-Arm
2.5 Pushrod Stainless steel has numerous properties that make it desirable
to use in the widespread manufacture of parts and
We chose push-rods that are made of Stainless Steel. components. The mechanical properties of one of the
Stainless steel is the name of a family of iron-based alloys frequently used grades of stainless steel, the 304 grade is as
known for their corrosion and heat resistance. One of the below:
main characteristics of stainless steel is its minimum
chromium content of 10.5%, which gives it superior Table 2: Mechanical Properties
resistance to corrosion in comparison to other types of steels. Properties Value
Like other steels, stainless steel is composed primarily from Density (x1,000 kg/m³) 8
iron and carbon, but with the addition of several other Poisson's ratio 0.27- 0.30
alloying elements, the most prominent being chromium. Elastic modulus (GPa) 193
Tensile strength (MPa) 515
Yield strength (MPa) 205
Force at the front side = mass at the rear side of the vehicle x
acceleration.
Let the mass at the rear side of the vehicle be 0.6 times the
2.6 Damper
total weight
We are going with DNM RCP2S shock absorbers because of
Mass at the rear side of the vehicle = 0.6 x 300 = 180kg
better quality and excellent shock absorbing abilities.
Vibrations can be damped easily.
Force = 180 x 9.81 = 1765.8 N
Damper calculations are done and eye to eye length of 210
Now force on each wheel = 1765.8/2 = 882.9N
mm is fixed with spring size = 12 mm. Spring travel = 61 mm
and mass of shock absorber = 0.41 kg.
Longitudinal Force = 882.9 N
Body is made up of dark hard anodized Al 7075 material to
3.2 Lateral Forces
have higher strength with low weight.
Lateral Forces are because of two reasons – centrifugal force
and lateral load transfer from outside to inside while turning.
The centrifugal force is considered as follows.
3.4.1 To choose Wishbone Material Step-6: Joining UBJ with IC, we will get the Upper Control
A prototype material “Chromoly” is taken for consideration. Arm axis and joining the LBJ with IC, we will get the Lower
Based on the shear strain (ɸ) value of chromoly, ɸ = 80 G Pa Control Arm axis.
(AISI 4130) = 80 x 10 3N/mm2 So, in the front view we will see UCA and LCA (Hard points
1, 2 and 3, 4)
Shear Modulus (G) = Shear Modulus of the front wishbone
(Gf) = 4.645 x 10 -4 (too small). Hence the material selected Step-7: Find the coordinates (x, y, and z) of these hard
undergoes much less deformation with a given load. The points.
material chosen is perfectly suitable for control arms. In the front view, we get only y, z coordinates. For x-
coordinate we should see the side view of the tire.
Rear wishbone Shear stress offered on the wishbone (τ) =
First moment of area of the wishbone (Q) = Qout - Qin
Volume 11 Issue 11, November 2022
www.ijsr.net
Licensed Under Creative Commons Attribution CC BY
Paper ID: SR221108085737 DOI: 10.21275/SR221108085737 577
International Journal of Science and Research (IJSR)
ISSN: 2319-7064
SJIF (2022): 7.942
Step-8: Assume Castor Angle for side view. Castor line is Step-13: Now join that point with IC, we will get the UCA
basically the side view of kingpin axis. axis.
Step-9: Extending UBJ up to Castor line, we will get x - Step-14: As we know the other pivot point of UCA is located
coordinate, similarly for LBJ. on the axis, similarly for LCA.
Step-10: Assuming Anti-dive% in Side View, which will Step-15: follow the same approach for rear (just mirror it).
give SVSA angle.
Step-16: Put all these suspension mounting points in lotus
Step-11: Keep SVSA L as short as possible because it shark. We also need to give basic inputs like type of
determines the pitching action of the vehicle, responsible for Suspension system, approach of our suspension, tire data,
applying moment at IC of side view. Wheelbase, Dive, Weight, etc and get respective graphs.
Line passing from SVSA L will intersect SVSA at IC.
Step-17: Analyse the Graphs, whether it is feasible or not for
Step-12: Add some distance to the center line in the right our requirements at static and dynamic conditions
direction because the front of the vehicle is towards the Finding suspension points is an iterative process and below is
right. the image of the line diagram of suspension points.
S. No X Y Z
7 1620 427.8 360.1
8 1620 551.5 192.1
Left hard points 9 1750 258.41 377.15
10 1750 345.11 234.47
11 1500 256.7 358.5
12 1500 242.07 202.03
Half Simulation
Full Simulation
Castor Angle
Camber Angle
Kingpin Angle
Specifications Front/Rear
Spring rate [N/mm] 86/77
Roll rate*104 [Nm/deg] 1477.54/1540.86
Ride rate [N/mm] 0.645/0.647
Wheel rate [N/mm] 140.15/146.53
Suspension travel [mm] 50 / 50
Max Damper stroke [mm] 76
Toe Angle CG height [mm] 375
Ground clearance [mm] 180
Castor [deg] 3
KPI [deg] 8
Scrub radius [mm] 55
Sprung mass [N] 392.266
Unsprung mass [N] 2353.596
Motion ratio 1.275 / 1.356
Roll center height [mm] 160
Roll gradient [rad/g] -0.068
7. Conclusion
The purpose of this project is not only to design and
manufacture the suspension system for the car, but also to
provide an in-depth study in the process taken to arrive at the
final design.
Anti Dive
The design is first conceptualized based on personal
experiences during the previous projects under SAE
competitions. Engineering principles and design processes
are then used to verify and create a vehicle with optimal
performance, safety, manufacturability and ergonomics.
High ground clearance as 180mm and the shock travel is
up to the maximum of 76mm, whereas the wishbone hard
points were mounted to the nodes of the triangulated
chassis where point can bear the peak number of stresses,
all the 8 hard points of the front suspension were mounted
to the nodes of the chassis systematically executed.
The distance between upper A-arm and lower A-arm is
168 mm and the distance between the knuckle upper A-
arm mounting point and lower A-arm mounting point is
Anti Squat 168 mm (parallel double wishbone suspension system).
The camber and toe angles can be controlled so that the
stress on the tie rod and steering arm will be less and less
6. Results
chances of failure.
Anti-dive feature reduces the jerking effect at the time of
Therefore, it can be considered that the optimized set of
braking.
values will render a very comfortable ride. The FEA result
Anti-squat feature reduces the jerking effect at the time of
indicates that the suspension system is able to perform safely
high acceleration
in real track condition as per performance requirement.
Aerodynamic stability is achieved by provision of low roll
center height at the front of the vehicle.
With the overall design being carefully considered
As the C.G height is kept near to the ground the rolling
beforehand, the manufacturing process being controlled
effect of vehicle is reduced.
closely, and many design features have been proven effective
Oversteer configuration enables good vehicle handling to
within the performance requirement of the vehicle.
the driver by reducing the required steering effort.
Oversteer configuration enables good vehicle handling to
the driver by reducing the required steering effort.
Volume 11 Issue 11, November 2022
www.ijsr.net
Licensed Under Creative Commons Attribution CC BY
Paper ID: SR221108085737 DOI: 10.21275/SR221108085737 581
International Journal of Science and Research (IJSR)
ISSN: 2319-7064
SJIF (2022): 7.942
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3.
Author Profile
Nagavarun Samala1 pursuing B.E degree in
Mechanical Engineering from Chaitanya Bharathi
Institute of Technology, Gandipet, Hyderabad. He
stayed as Suspension Engineer since 2019 and
participated in Formula Bharat 2019, served as Design
Engineer and participated in Formula Green Concept 2021 and
Formula Imperial 2022, currently working as Robotic engineer in
Kitolit and EV Chief in Praheti Racing, Formula Student Club,
CBIT.