Automotive suspension design process

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Automotive suspension design is an aspect of automotive engineering, concerned with designing the suspension for cars and trucks. Suspension design for other vehicles is similar, though the process may not be as well established.

Automotive engineering, along with aerospace engineering and naval architecture, is a branch of vehicle engineering, incorporating elements of mechanical, electrical, electronic, software, and safety engineering as applied to the design, manufacture and operation of motorcycles, automobiles, and trucks and their respective engineering subsystems. It also includes modification of vehicles. Manufacturing domain deals with the creation and assembling the whole parts of automobiles is also included in it. The automotive engineering field is research -intensive and involves direct application of mathematical models and formulas. The study of automotive engineering is to design, develop, fabricate, and test vehicles or vehicle components from the concept stage to production stage. Production, development, and manufacturing are the three major functions in this field.

Contents

The process entails

Ball joint

In an automobile, ball joints are spherical bearings that connect the control arms to the steering knuckles. They are used on virtually every automobile made and work similarly to the ball-and-socket design of the human hip joint.

Bushing (isolator) bushing

A bushing or rubber bushing is a type of vibration isolator. It provides an interface between two parts, damping the energy transmitted through the bushing. A common application is in vehicle suspension systems, where a bushing made of rubber separates the faces of two metal objects while allowing a certain amount of movement. This movement allows the suspension parts to move freely, for example, when traveling over a large bump, while minimizing transmission of noise and small vibrations through to the chassis of the vehicle. A rubber bushing may also be described as a flexible mounting or antivibration mounting.

Shock absorber mechanical or hydraulic device designed to absorb, smooth out or damp any sudden shock impulse and dissipate kinetic energy (typically heat); usually consists of a combination of a spring and a dashpot; most shock absorbers are a form of dashpot

A shock absorber or damper is a mechanical or hydraulic device designed to absorb and damp shock impulses. It does this by converting the kinetic energy of the shock into another form of energy which is then dissipated. Most shock absorbers are a form of dashpot.

Since the 1990s the use of multibody simulation and finite element software has made this series of tasks more straightforward.

Vehicle level targets

A partial list would include:

Roll moment is a moment, which is a product of a force and a distance, that tends to cause a vehicle to roll, that is to rotate about its longitudinal axis.

Turning radius radius of smallest circle a particular vehicle can turn along

The turning radius or turning circle of a vehicle is the radius of the smallest circular turn that the vehicle is capable of making.

Ackermann steering geometry

Ackermann steering geometry is a geometric arrangement of linkages in the steering of a car or other vehicle designed to solve the problem of wheels on the inside and outside of a turn needing to trace out circles of different radii.

Once the overall vehicle targets have been identified they can be used to set targets for the two suspensions. For instance, the overall understeer target can be broken down into contributions from each end using a Bundorf analysis.

A Bundorf analysis is a measure of the characteristics of a vehicle that govern its understeer balance. The understeer is measured in units of degrees of additional yaw per g of lateral acceleration.

System architecture

Typically a vehicle designer is operating within a set of constraints. The suspension architecture selected for each end of the vehicle will have to obey those constraints. For both ends of the car this would include the type of spring, location of the spring, and location of the shock absorbers.

For the front suspension the following need to be considered

For the rear suspension there are many more possible suspension types, in practice.

Hardpoints

The hardpoints control the static settings and the kinematics of the suspension.

The static settings are

The kinematics describe how important characteristics change as the suspension moves, typically in roll or steer. They include

The analysis for these parameters can be done graphically, or by CAD, or by the use of kinematics software.

Compliance analysis

The compliance of the bushings, the body, and other parts modify the behaviour of the suspension. In general it is difficult to improve the kinematics of a suspension using the bushings, but one example where it does work is the toe control bush used in Twist-beam rear suspensions. More generally, modern cars suspensions include a Noise, vibration, and harshness (NVH) bush. This is designed as the main path for the vibrations and forces that cause road noise and impact noise, and is supposed to be tunable without affecting the kinematics too much.

In racing cars, bushings tend to be made of harder materials for good handling such as brass or delrin. In Passenger cars, bushings tend to be made of softer material for added comfort. In general physical terms, the mass and mechanical hysteresis (damping effect) of solid parts should be accounted for in a dynamic analysis, as well as their elasticity.

Loads

Once the basic geometry is established the loads in each suspension part can be estimated. This can be as simple as deciding what a likely maximum load case is at the contact patch, and then drawing a Free body diagram of each part to work out the forces, or as complex as simulating the behaviour of the suspension over a rough road, and calculating the loads caused. Often loads that have been measured on a similar suspension are used instead - this is the most reliable method.

Detailed design of arms

The loads and geometry are then used to design the arms and spindle. Inevitably some problems will be found in the course of this that force compromises to be made with the basic geometry of the suspension.

Related Research Articles

For vehicles such as cars, vehicle dynamics is the study of how the vehicle will react to driver inputs on a given solid surface.

Camber angle

Camber angle is the angle made by the wheels of a vehicle; specifically, it is the angle between the vertical axis of the wheels used for steering and the vertical axis of the vehicle when viewed from the front or rear. It is used in the design of steering and suspension. If the top of the wheel is farther out than the bottom, it is called positive camber; if the bottom of the wheel is farther out than the top, it is called negative camber.

MacPherson strut axle

The MacPherson strut is a type of automotive suspension system that uses the top of a telescopic damper as the upper steering pivot. It is widely used in the front suspension of modern vehicles and is named for American automotive engineer Earle S. MacPherson, who invented and developed the design.

Steering collection of components, linkages, etc. which allows any vehicle to follow the desired course (for directional control)

Steering is the collection of components, linkages, etc. which allows any vehicle to follow the desired course. An exception is the case of rail transport by which rail tracks combined together with railroad switches provide the steering function. The primary purpose of the steering system is to allow the driver to guide the vehicle.

Multi-link suspension

A multi-link suspension is a type of vehicle suspension design typically used in independent suspensions, using three or more lateral arms, and one or more longitudinal arms. A wider definition considers any independent suspensions having three control links or more multi-link suspensions. These arms do not have to be of equal length, and may be angled away from their "obvious" direction. It was first introduced in the late 1960s on the Mercedes-Benz C111 and later on their W201 and W124 series.

Car suspension system of tires, tire air, springs, shock absorbers and linkages that connects a vehicle to its wheels and allows relative motion between the two

Suspension is the system of tires, tire air, springs, shock absorbers and linkages that connects a vehicle to its wheels and allows relative motion between the two. Suspension systems must support both road holding/handling and ride quality, which are at odds with each other. The tuning of suspensions involves finding the right compromise. It is important for the suspension to keep the road wheel in contact with the road surface as much as possible, because all the road or ground forces acting on the vehicle do so through the contact patches of the tires. The suspension also protects the vehicle itself and any cargo or luggage from damage and wear. The design of front and rear suspension of a car may be different.

Slip angle

In vehicle dynamics, slip angle or sideslip angle is the angle between the direction in which a wheel is pointing and the direction in which it is actually traveling. This slip angle results in a force, the cornering force, which is in the plane of the contact patch and perpendicular to the intersection of the contact patch and the midplane of the wheel. This cornering force increases approximately linearly for the first few degrees of slip angle, then increases non-linearly to a maximum before beginning to decrease.

Understeer and oversteer

Understeer and oversteer are vehicle dynamics terms used to describe the sensitivity of a vehicle to steering. Oversteer is what occurs when a car turns (steers) by more than the amount commanded by the driver. Conversely, understeer is what occurs when a car steers less than the amount commanded by the driver.

Automobile handling and vehicle handling are descriptions of the way a wheeled vehicle responds and reacts to the inputs of a driver, as well as how it moves along a track or road. It is commonly judged by how a vehicle performs particularly during cornering, acceleration, and braking as well as on the vehicle's directional stability when moving in steady state condition.

Double wishbone suspension Automobile Suspension

In automobiles, a double wishbone suspension is an independent suspension design using two wishbone-shaped arms to locate the wheel. Each wishbone or arm has two mounting points to the chassis and one joint at the knuckle. The shock absorber and coil spring mount to the wishbones to control vertical movement. Double wishbone designs allow the engineer to carefully control the motion of the wheel throughout suspension travel, controlling such parameters as camber angle, caster angle, toe pattern, roll center height, scrub radius, scuff and more.

Caster angle

The caster angle or castor angle is the angular displacement of the steering axis from the vertical axis of a steered wheel in a car, motorcycle, bicycle, other vehicle or a vessel, measured in the longitudinal direction. It is the angle between the pivot line and vertical. In automobile racing, the caster angle may be adjusted to optimize handling characteristics for a particular venue.

Toe (automotive)

In automotive engineering, toe, also known as tracking, is the symmetric angle that each wheel makes with the longitudinal axis of the vehicle, as a function of static geometry, and kinematic and compliant effects. This can be contrasted with steer, which is the antisymmetric angle, i.e. both wheels point to the left or right, in parallel (roughly). Negative toe, or toe out, is the front of the wheel pointing away from the centerline of the vehicle. Positive toe, or toe in, is the front of the wheel pointing towards the centerline of the vehicle. Toe can be measured in linear units, at the front or rear of the tire, or as an angular deflection.

A swing axle is a simple type of independent suspension designed and patented by Edmund Rumpler in 1903. This was a revolutionary invention in the automotive industry, allowing wheels to react to irregularities of road surfaces independently, and enable the vehicle to maintain a strong road holding. The first automotive application was the Rumpler Tropfenwagen, later followed by the Mercedes 130H/150H/170H, the Standard Superior, the Volkswagen Beetle and its derivatives, and the Chevrolet Corvair, amongst others.

Anti-roll bar

An anti-roll bar is a part of many automobile suspensions that helps reduce the body roll of a vehicle during fast cornering or over road irregularities. It connects opposite (left/right) wheels together through short lever arms linked by a torsion spring. A sway bar increases the suspension's roll stiffness—its resistance to roll in turns, independent of its spring rate in the vertical direction. The first stabilizer bar patent was awarded to Canadian inventor Stephen Coleman of Fredericton, New Brunswick on April 22, 1919.

The roll center of a vehicle is the notional point at which the cornering forces in the suspension are reacted to the vehicle body.

Tilting three-wheeler

A tilting three-wheeler, or tilting trike is a three-wheeled vehicle whose body and or wheels tilt in the direction of a turn, and is usually a narrow-track vehicle. Such vehicles can corner without rolling over despite having a narrow axle track because they can balance some or all of the roll moment caused by centripetal acceleration with an opposite roll moment caused by gravity, as bicycles and motorcycles do. This also reduces the lateral acceleration experienced by the rider, which some find more comfortable than the alternative. The narrow profile can result in reduced aerodynamic drag and increased fuel efficiency. These types of vehicles have also been described as "man-wide vehicles" (MWV).

Beam axle

A beam axle, rigid axle or solid axle is a dependent suspension design, in which a set of wheels is connected laterally by a single beam or shaft. Beam axles were once commonly used at the rear wheels of a vehicle, but historically they have also been used as front axles in rear-wheel-drive vehicles. In most automobiles, beam axles have been replaced by front and rear independent suspensions.

Bump steer tendency for car to steer itself

Bump steer or roll steer is the term for the tendency of the wheel of a car to steer itself as it moves through the suspension stroke. It is typically measured in degrees of steer per metre of upwards motion or degrees per foot.

Twist-beam rear suspension

The twist-beam rear suspension is a type of automobile suspension based on a large H or C shaped member. The front of the H attaches to the body via rubber bushings, and the rear of the H carries each stub-axle assembly, on each side of the car. The cross beam of the H holds the two trailing arms together, and provides the roll stiffness of the suspension, by twisting as the two trailing arms move vertically, relative to each other.

References

Notes

    Sources

    Simulation and direct equations: Abramov, S., Mannan, S., & Durieux, O. (2009)'Semi-Active Suspension System Simulation Using SIMULINK'. International Journal of Engineering Systems Modelling and Simulation, 1(2/3), 101 - 114 http://collections.crest.ac.uk/232/1/fulltext.pdf