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Ganzi Suresh
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Ganzi Suresh
Aim of this project is to optimize the thickness of the upper control arm of wishbone
suspension system to loading. The present project work has created a Finite Element Model
for wishbone suspension using HYPERMESH V11. Pre- Processing steps such as updating of
element type, material properties, application of loads and boundary conditions. The element
type considered for the analysis is second order R- Trais, meshing type is tetra mesh.
DESIGN OPTIMIZATION OF A WISHBONE SUSPENSION
OF A PASSENGER CAR
A Thesis
Submitted in partial fulfillment of the Requirements for the award of the Degree in
Master of Technology
In
Mechanical Engineering
(Product Design)
By
GANZI SURESh
Roll No: 11001D3407
I would like to thank Dr. B. DurgaPrasad M.Tech., P.h.D. Professor Mechanical Engineering
Dept, JNTUCEA, Ananthapuram,, for advising this work and for allowing me the freedom to
pursue this optimization project. His advice and leadership was plentiful and much
appreciated.
I would also like to acknowledge Dr. M. YOHAN M.Tech., Ph.D. Professor & Head of
Mechanical Engineering Dept, JNTUCEA, Ananthapuram, who has been inspiring and
encouraging throughout the project.
I am also very thankful to the entire Faculty and Non-Teaching staff of Mechanical
Engineering Dept, for their support and cooperation.
I regret, if any acknowledgement that is due has been missed out or found inadequate.
With Regards,
Ganzi Suresh.
The double wishbone configurations can give vertical movement close to perpendicular
relative to the tier-contact surface. The wishbone linkages arrangement provides very good
wheel adhesion and optimum wheel control. In addition, the double wishbone suspension
system provides a whole new range of possibilities in regard to the application of computer
systems which would provide active suspension control to suit various conditions.
The main aim of this project is to optimize the thickness of the upper control arm of
wishbone suspension system to loading. The present project work has created a Finite
Element Model for wishbone suspension using HYPERMESH V11. Pre- Processing steps
such as updating of element type, material properties, application of loads and boundary
conditions. The element type considered for the analysis is second order R- Trais, meshing
type is tetra mesh.
Processing is done internally mathematical equations by the software. The results in the form
of stress deformation are shown by contour plots. The factor of safety for the upper control
arm calculated, based on von-Misses theory of failure is found to be 5.64. Desired factor of
safety for the suspension components in 3.49. Therefore there is need to optimize the upper
control arm.
Optimization of the thickness of upper control arm of wishbone suspension system is done in
terms of reduction in its weight and there by the fixed cost, operation cost are decreased
drastically. Thickness of the control arm is varied in different steps to optimize it, so as a
factor of safety of 3.5 is obtained. It is found to be 10mm thickness for upper control arm
satisfies the strength criteria and the factor of safety is within the limits.
CONTENTS 5
LIST OF FIGURES 8
LIST OF TABLES 11
NOMENCLATURE 12
CHAPTER: 1 INTRODUCTION:
1.1 Suspension system 13
4.2 Radioss 36
4.3 Hyperview 36
CHAPTER: 6 PROCESSING
6.1 Set up for design space 49
CHAPTER: 7 ANALYSIS
7.1 Linear Static Analysis 53
CHAPTER: 8 POST-PROCESSING
8.1 Comparison of results - Linear Static Analysis 66
REFERENCE 72
15 mm thickness mode 1 62
10
11
Kg = Kilogram
Mm = Millimeter
M pa = Mega Pascal 12
SF = Safety Factor
σ = Stress
ɛ = Strain
ρ = Density
µ = Poisson’s ratio
∑ = Summation
D = Dimension
Π = Pie
r = Radius
N = Newton
E = Elastic Modulus
13
INTRODUCTION
1.1.1 History
Leaf springs have been around since the early Egyptians. Ancient military engineers used leaf
springs in the form of bows to power their siege engines, with little success at first. The use
of leaf springs in catapults was later refined and made to work years later. Springs were not
only made of metal, a sturdy tree branch could be used as a spring, such as with a bow.
The British steel springs were not well suited for use on America's rough roads of the time,
and could even cause coaches to collapse if cornered too fast. In the 1820s, the Abbot
Downing Company of Concord, New Hampshire re-discovered the antique system whereby
the bodies of stagecoaches were supported on leather straps called "thorough braces", which
gave a swinging motion instead of the jolting up and down of a spring suspension (the
stagecoach itself was sometimes called a "thorough brace").
1.1.3 Automobiles
The purpose of the complete suspension system is to isolate the vehicle body from road
shocks and vibrations which would otherwise be transferred to the passengers and load. It
must also keep the tires in contact with the road, regardless of road surface. A basic
suspension system consists of springs, axles, shock absorbers, arms, rods, and ball joints. The
spring is the flexible component of the suspension. Basic types are leaf springs, coil springs,
and torsion bars. Modern passenger vehicles usually use light coil springs. Light commercial
vehicles have heavier springs than passenger vehicles, and can have coil springs at the front
and leaf springs at the rear.
The study of the forces at work on a moving car is called vehicle dynamics. Some of the
concepts are needed to be understood in order to appreciate why a suspension is necessary in
the first place. Most automobile engineers consider the dynamics of a moving car from these
perspectives:
These two characteristics can be further described in three important principles - Road
Isolation, Road Holding and Cornering. These principles are explained below and also how
engineers attempt to solve the challenges unique to each.
1.2.3 Road Isolation – The vehicle's ability to absorb or isolate road shock from the
passenger compartment. Allow the vehicle body to ride undisturbed while traveling over
rough roads. Absorb energy from road bumps and dissipate it without causing undue
oscillation in the vehicle.
1.2.4 Road Holding – The degree to which a car maintains contact with the road surface in
various types of directional changes and in a straight line (Example: The weight of a car will
shift from the rear tires to the front tires during braking. Because the nose of the car dips
toward the road, this type of motion is known as "dive". The opposite effect "squat" occurs
during acceleration, which shifts the weight of the car from the front tires to the back.
Minimize the transfer of vehicle weight from side to side and front to back, as this transfer of
weight reduces the tire's grip on the road.
1.2.5 Cornering – It is the ability of a vehicle to travel a curved path. Minimize body roll,
which occurs as centrifugal force pushes outward on a car's center of gravity while cornering,
raising one side of the vehicle and lowering the opposite side. Transfer the weight of the car 15
during cornering from the high side of the vehicle to the low side.
Dependent suspension systems get their name because each of the front or rear wheels is
dependent on the wheel opposite of it. This type of suspension system is only found on
modern trucks and off road vehicles but a number of years ago it was common on cars as
well. The major downside to a dependent suspension system is that the wheels are linked, if
one wheel is set into oscillation and the other is not, it sets up a gyroscopic torque around the
steering axis. This force will start to turn the axle left to right and due to the axles inertia, it
will amplify the force of the original oscillation. To put that simpler, if the tire on the right
side hits a bump it will directly affect the left side and can even cause a larger effect than the
original bump. Another downfall of a dependent suspension system is that it weighs more
than an independent system. This is because there are a number of parts that are needed on a
dependent system that are not needed on an independent system.
A beam axle is a suspension system, also called a solid axle, in which one set of wheels is
connected laterally by a single beam or shaft. A live axle is a type of beam axle in which the
shaft (or shafts, since live axles, while connected to move as a single unit, are seldom one
piece) also transmits power to the wheels; a beam axle that does not also transmit power is
sometimes called a dead axle. Beam axles are commonly used at the rear wheels of a vehicle,
but historically they have also been used as front axles in rear-wheel-drive cars. Ford used
beam axles across the range until 1949, only being phased out in Europe as recently as the
early 1960s with the Ford Popular being suspended.
Beam axles are typically suspended either by leaf springs or coil springs. In some cases, a
Pan hard rod or similar device may be used to control the lateral motion of the axle. A similar
suspension is the Twist-beam rear suspension, in which the beam axle also functions as an
anti-roll bar to control the roll motion of the body. The principal advantage of the beam axle
is that it is simple and cheap to manufacture. It also engages little or no interior volume 16
within the vehicle. Its drawbacks are that it does not allow each wheel to move independently
in response to bumps, and the mass of the beam is part of the unsprung weight of the vehicle,
which can further reduce ride quality
A beam axle is a suspension system, also called a solid axle, in which one set of wheels is
connected laterally by a single beam or shaft
Because beam axles do not ever exhibit any camber change as the suspension travels, they are
ideal for carrying heavy or varying loads. Although this negatively impacts cornering
compared to other suspension designs (because the wheels have zero camber gain during
body roll), beam axles are nearly universally used in heavy-duty trucks. One notable
exception is the Czech manufacturer Tatra, who instead use swing-axles in conjunction with a
central 'backbone' chassis. Most light and medium duty pickup trucks and vans also use a
beam axle, at least in the rear. Beam axles have an important advantage for off-road
applications, as they provide better vehicle articulation and durability in a high load
environment.
On front-wheel-drive vehicles, a simple beam axle can be used on the rear, with coil spring
suspension and control arms for location. This is called a dead axle, since it only supports the
vehicle and doesn’t transmit any drive. It is also non-independent, as deflection of a wheel on
one side of the vehicle will be transferred to the other wheel. On some vehicles, this is
reduced by using a U-shaped axle beam, with a torsion bar mounted inside it. Trailing arms
are welded to the beam, to locate the axle longitudinally. A lateral rod prevents lateral
movement when cornering, and coil springs provide for suspension. The torsion bar is
connected between the left and right wheel units, and deflection of the wheel on one side
causes the axle and its torsion bar to twist together. Passenger cars no longer use beam axle
front suspension, but it is still common on heavy commercial vehicles, and some 4-wheel-
drives.Trucks use an I-beam, in most cases located by leaf springs.
Coil springs may also be used for front and rear, and as with other beam axle designs, control
arms and a lateral rod must be used for location.
17
An independent suspension system gets its name because the wheels on either side of the car
are independent from one another. The only exception to this is an anti-roll bar that connects
the two wheels, to prevent the cars suspension from rolling as it corners. There are a number
of independent suspension types such as, coil spring type 1, coil spring type 2, multi-link,
trailing-arm, twin I-beam, moulton rubber and transverse leaf spring. The major difference
between independent suspension and dependent suspension is that when a car with
independent suspension hits a bump it only affects the wheel that hit the bump. This offers
many advantages such as, better ride comfort, better traction, more stability and an overall
safer vehicle.
A MacPherson strut is a type of shock absorber that has a more structural role in a vehicle’s
suspension. Named after its creator, “MacPherson strut” refers both to the component and
the suspension design that employs it. The strut includes a shock absorber element but also
plays a role in positioning the wheels. Struts are used for the front or rear axle or both and are
the most common suspension type in passenger cars today. Each strut runs directly through a
coil spring and resides in a tall channel called a tower, the top of which may be visible under
the hood near the back of the engine compartment. This “coil-over” design is space efficient,
as is the strut’s elimination of the space-robbing upper control arm used in earlier suspension
designs. The low overall parts count reduces the unspring weight, for a smoother ride. Struts 18
are also used in a modified MacPherson design that locates the springs inboard, rather than
around the struts an approach that’s claimed to reduce vibration in the steering wheel.
The double wishbone suspension is a very popular type of suspension foundon mid-range to
high-end cars. It is an independent suspension design using two (occasionally parallel)
wishbone-shaped arms to locate the wheel as shown in Fig. 1.4. Each wishbone or arm has
two mounting points connected to the chassis and one joint at the knuckle to accept the
steering input. The shock absorber and coil spring are mounted on the wishbones to control
its vertical movement. Double wishbone designs allow the engineer to carefully control the
motion of the wheel throughout the suspension travel, controlling parameters such as camber
angle, caster angle, toe, roll centre height, scrub radius, scuff and more thereby resulting in a
better tuned suspension system for good ride, handling etc. These parameters affect factors
from lateral force to steering effort to anti-dive/ant-squat characteristics of the vehicle. Two
of the wheel parameters that significantly affect the car handling characteristics are camber
and toe. 19
Chapter 2 discusses about the literature survey carried out in order to understand the
suspension system, mechanism and concept of optimization. It also gives brief introduction of
Factor of Safety.
Chapter 3 deals with Finite Element Analysis like methods followed in FEM. It discusses
both theoretical and software based FEM. It gives description about the types of analysis
followed in industries and engineering application of optimization.
Chapter 4 constitute the software review as Hypermesh v11, Radioss and Optistruct.
Chapter 6 constitute processing as setup for the design space and load calculations.
20
Chapter 7 discusses about the Analysis like linear static analysis, buckling analysis and
modal analysis.
Chapter 9 gives a result summary, conclusion and scope for the future work that can be
carried out.
21
LITERATURE REVIEW
2.1.1 Implementation
The double-wishbone suspension can also be referred to as "double A-arms," though the arms
themselves can be A-shaped, L-shaped, or even a single bar linkage. A single wishbone or A-
arm can also be used in various other suspension types, such as MacPherson strut and
Chapman strut. The upper arm is usually shorter to induce negative camber as the suspension
jounces (rises), and often this arrangement is titled an "SLA" or "short long arms"
suspension.
When the vehicle is in a turn, body roll results in positive camber gain on the lightly loaded
inside wheel, while the heavily loaded outer wheel gains negative camber. Between the
outboard end of the arms is a knuckle with a spindle (the kingpin), hub, or upright which
22
carries the wheel bearing and wheel. Negative response of the vehicle is affected by camber
angle in three following cases:
In zero camber case, the wheel is perpendicular to the road surface and its steering is
relatively difficult. This case is used in tracks.
Negative camber case for separate suspension systems to increase the level of reliance
vehicle on the road, is used in back wheels, but not in front wheels
Positive camber for front wheels between 0 to 2degrees is selected because:
* In the positive camber, the lateral force is cause to direct wheel upward and thus the force
on the trunnion nut removed and the two cone bearing will be established well(Fig 2.3).
When the wheel is lie under the loads, it could be lie in vertical state. Whenever camber angle
is not positive, bending moment take the front wheels to the negative camber case. Positive 23
camber angle causes that front wheels lie under full load and then the wheels lie in vertical
state.
At the knuckle end, single ball joints are typically used, in which case the steering loads have
to be taken via a steering arm, and the wishbones look A- or L-shaped. An L-shaped arm is
generally preferred on passenger vehicles because it allows a better compromise of handling
and comfort to be turned in. The bushing in line with the wheel can be kept relatively stiff to
effectively handle cornering loads while the off-line joint can be softer to allow the wheel to
recess under fore-aft impact loads. For a rear suspension, a pair of joints can be used at both
ends of the arm, making them more H-shaped in plan view. Alternatively, a fixed-length
driveshaft can perform the function of a wishbone as long as the shape of the other wishbone
provides control of the upright. This arrangement has been successfully used in the Jaguar
IRS. In elevation view, the suspension is a 4-bar link, and it is easy to work out the camber
gain (see camber angle) and other parameters for a given set of bushing or ball-joint
locations. The various bushings or ball joints do not have to be on horizontal axes, parallel to
the vehicle centre line. If they are set at an angle, then anti-dive and anti-squat geometry can
be dialed in.
In many racing cars, the springs and dampers are relocated inside the bodywork. The
suspension uses a bell crank to transfer the forces at the knuckle end of the suspension to the
internal spring and damper. This is then known as a "push rod" if bump travel "pushes" on
the rod (and subsequently the rod must be joined to the bottom of the upright and angled
upward). As the wheel rises, the push rod compresses the internal spring via a pivot or
pivoting system. The opposite arrangement, a "pull rod," will pull on the rod during bump
travel, and the rod must be attached to the top of the upright, angled downward. Locating the
spring and damper inboard increases the total mass of the suspension, but reduces the
unsprung mass, and also allows the designer to make the suspension more aerodynamic.
Advantages include that it provides the engineer more free parameters than some other types
do. It is fairly easy to work out the effect of moving each joint, so the kinematics of the
suspension can be turned easily and wheel motion can be optimized. It is also easy to work
out the loads that different parts will be subjected to which allows more optimized
lightweight parts to be designed. They also provide increasing negative camber gain all the
way to full jounce travel, unlike the MacPherson strut, which provides negative camber gain
only at the beginning of jounce travel and then reverses into positive camber gain at high
jounce amounts.
The disadvantages are that it may take more space and is slightly more complex than other
systems like a MacPherson strut. Due to the increased number of components within the
suspension setup it takes much longer to service and is heavier than an equivalent
MacPherson design.
24
The double wishbone suspension was introduced in the 1930s. French carmaker Citroën used
it since 1934 in their Rosalie and Traction Avant models. Packard Motor Car Company of
Detroit, Michigan used it on the Packard One-Twenty from 1935, and advertised it as a safety
feature. Prior to the dominance of front wheel drive in the 1980s, many everyday cars used
double wishbone front-suspension systems or a variation on it. Since that time, the
MacPherson strut has become almost ubiquitous, as it is simpler and cheaper to manufacture.
In most cases, a MacPherson strut requires less space to engineer into a chassis design, and in
front-wheel-drive layouts, can allow for more room in the engine bay.
A good example of this is observed in the Honda Civic, which changed its front-suspension
design from a double wishbone to a MacPherson strut after the year 2000 model.
Double wishbones are usually considered to have superior dynamic characteristics as well as
load-handling capabilities, and are still found on higher performance vehicles. Examples of
makes in which double wishbones can be found include Alfa Romeo, MG, Pontiac, Honda
and Mercedes-Benz. Short long arms suspension, a type of double wishbone suspension, is
very common on front suspensions for medium-to-large cars such as the Honda Accord
(replaced by MacPherson struts in 2013+ models), Peugeot 407, or Mazda 6/Atenza, and is
very common on sports cars and racing cars. It also provides least camber change at bump
and rebound condition.
Optimization is the act of obtaining the best results under given circumstances. In design, and
maintenance of any engineering system, engineers have to take many technological and
managerial decisions at several stages. The ultimate goal of all such decisions is either to
minimize the effort required or to maximize the desire benefits. Since the effort required or 25
the benefit desired in any practical situation can be expressed as a function of certain decision
variables, optimization can be defined as the process of finding the conditions that give the
maximum or minimum value of a function.
It is a common practice to size the machine elements, so that the maximum design stress is
below the UTS (Ultimate Tensile Stress) or yield stress by an appropriate factor – the Factor
of Safety. Factor of Safety is used to provide a design margin over the theoretical design
capacity to allow for uncertainty in the design process. Factor of safety is recommended by
the conditions over which the designer has no control that is to account for the uncertainties
involved in the design process. Many systems are purposefully built much stronger than
needed for normal usage to allow for emergency situation, unexpected loads, misuses or
degradation.
There are two distinct uses of safety: One as a ratio of absolute strength (structural capacity)
to actual applied load. This is a measure of the reliability of a particular design. The other use
of FOS is a constant value imposed by law, standard specification, contract or custom to
which a structure must conform or exceed.
When the vehicle passes on them we experience the sudden motion along with the vehicle, it
is very un comfort to the passengers.
Here, the design of a suspension system comes in to picture. The new design should be such
that, it can withstand / absorb the cushions and it should not transfer those motions to the
passengers. It should posses the smooth and safe ride to the passengers in the vehicle.
27
3.1 Def : FEM is a computer aided numerical method used to obtain solutions for physical
and analytical problems whose behavior is explained by the solution of calculus, linear
algebra, differential equations.
FEM is a -
A numerical method
Mathematical representation of actual problem
Approximate method
3.1.1 Finite - Any continuous object has infinite degrees of freedom & it's just not possible
solve the problem in this format. Finite Element Method reduces degrees of freedom from.
Infinite-to-Finite with the help of discretization i.e. meshing (nodes & elements).
3.1.2 Element - All the calculations are made at limited number of points known as nodes.
Entity joining nodes and forming a specific shape such as quadrilateral or triangular etc is
known as Element. To get value of variable (Say displacement) anywhere in between the
calculation points, interpolation function (as per the shape of element) is used.
3.2 METHODS : There are three methods to solve any engineering problem,
28
Table : 3.1
Relative Design: In industry usually basic design of a category of components remains same
over the years. Say for example existing vehicle power is to be increased from 100 hp to
125hp. Basic design (shape and concept) of components would remain same with minor
changes like scaling the basic design in appropriate proportions. Suppose CAE model &
analysis of the previous version which is performing satisfactorily in the field, is available. If
Analysis of new design (using same element type and size with appropriate loads) shows
stress magnitude less-
than or equal to previous model then it could be concluded that the new upgraded design is
also safe and will perform satisfactorily. This way one can also avoid test correlation for new
model.
Sometimes too much emphasis is given to test correlation & accuracy of the FE model to
minute level. Too much attention to capture each and every detail complicates FE modeling
and analysis unnecessarily (such as modeling bolt threads when main objective is component
design rather than bolt, defining non linear contacts when simple linear connection can work
or dense mesh in the name of accuracy without due consideration for hardware and software
29
capabilities etc.).
Absolute Design: This approach is useful when the product / component is designed for the
first time 'i.e. innovative design and no previous record of similar product is available. The
M.Tech, Product Design | Jawaharlal Nehru Technological University Ananthapuram, 2011-13.
design engineer himself not very sure about boundary conditions & various load cases. CAE
results of such a design must be verified properly via testing and FE model should be
corrected in case of variation in the test & FEA results.
Direct Method - Easy to understand but difficult to program. It is not used for commercial
software code generation.
Variation Method - Rayleigh- Ritz Method : difficult to understand moderate from code
writing point of view.
Weighted Residual Method - Galerkin Method : difficult to understand but easy from
programming point of view. This method is used in most of the commercial software’s.
CAD & Meshing -There are specialized software’s for CAD, Meshing & Analysis. CAD and
meshing consumes most of the time. For example - Typical time for a single person to mode1
(CAD) four cylinder engine block is 6 weeks & for brick meshing 7 weeks (For tetra mesh
about 2 weeks).
30
Boundary Conditions - Consumes least time but it is the most Important step (typically
applying10 load cases is about 1 day job). Three months hard work of meshing & CAD data
preparation of engine block would be undone in just one day if boundary conditions are not
applied properly. After completion of preprocessing i.e. CAD, Meshing and Boundary
M.Tech, Product Design | Jawaharlal Nehru Technological University Ananthapuram, 2011-13.
conditions, software internally forms mathematical equations of the form [F] = [ K] [µ]
.
Today we are using FEA just because of availability of computers. FEM has been known to
mathematicians and engineers right from late 50's but since solving so many equations
manually was not possible, in true sense FEA got recognition only after emergence of high
capacity computers.
At the moment Indian Auto sector is experiencing a boom but from 1995 to 2003 there was a
slack. During the period most of industries were busy with cost cutting measures for their
survival.
In Indian market till late 80% same kind of vehicles were running on the road without any
change. These designs were transferred to Indian companies in 50's & 60's from their
overseas collaborators. Design philosophy was different at that time i.e. design for infinite
life. But slack in the market and emergence of new tools like CAD/CAM/CAE, new cost
efficient manufacturing techniques and availability of low cost materials forced auto
manufacturers to adapt to the changing circumstances via optimization of design. Suppose 31
selling price of the product is Rs.100 & actual manufacturing cost is Rs. 60. Reduction of
cost even by say Rs.1 by using CAD / CAM / CAE (reduction in thickness, change in
material etc.) will result in lot of profit for the company.
It is also possible to test a physical object to determine its natural frequencies and mode
shapes. This is called an Experimental Modal Analysis. The results of the physical test can be
used to calibrate a finite element model to determine if the underlying assumptions made Ire
correct (for example, correct material properties and boundary conditions are used).
3.7 OPTIMIZATION
- Geometrical Parameters,
- Shape Optimization.
Geometrical Parameters:
- Optimization for geometry parameters, work well at individual component level
33
rather than complicated assemblies.
- Software can not add or remove geometry on its own but can play with only pre
defined parameters within specified limits.
Optimization in its broadest sense can be applied to solve any engineering problem.
To indicate the wide scope of the subject, some typical applications from different
engineering disciplines are given below.
34
SOFTWARE REVIEW
Open-Architecture Design - With the broadest set of direct CAD and CAE interface
coupled with user defined integration, Hyper mesh fits seamlessly within any
simulation environment.
High-Speed, High-Quality Meshing - With both automatic and semi-automatic
shell, tetra- and hexa-meshing capabilities. Hyper mesh simplifies the modeling
process of complex geometries.
Advanced Model Morphing - A flexible set of morphing tools allows user to modify
existing meshes to meet new designs and reduce model development costs.
Reduce Model Assembly Time - Leverage highly Automated methods for rapid
model assembly that create connection such as bolts, spot welds, adhesive and seam
welds.
4.2 RADIOSS:
RADIOSS is comprehensive analysis capabilities for linear and non-linear finite element
analysis, sheet metal stamping, and multi-body dynamics are accessible via two input
formats.
4.2.1 Benefits
Structural Simulation -
Easily simulate dynamic loading events including crash, shock, impact, earthquake,
wave propagation, etc.
Linear and nonlinear vibration analysis (modal and frequency domain)
Linear and nonlinear static analysis
Preferred Crash and Safety Performance Solution RADIOSS includes a broad,
correlated set of barriers, impactors, and occupant models. Coupled with Hyper
Crash, RADIOSS provides a highly-tuned and automated crash simulation
environment.
4.3 HYPERVIEW :
Altair Hyper view is a complete post-processing and visualization environment for finite
element analysis, multi-body system simulation, digital video, and engineering data. Hyper
view combines advanced animation and XY plotting features with window synching to
enhance results visualization. Hyper view also saves 3D animation results in Altair's compact
H3D format, so users can visualize and share CAE results within a 3D Ib environment using
Altair Hyper View Player. Amazingly fast 3D graphics and unparalleled functionality set a 36
new standard for speed and integration of CAE results post-processing. Coupling these
features with Hyper view’s advanced process automation tools dramatically improves results
visualization and reporting.
PRE-PROCESSING
This is a full model of a front / rear double wishbone suspension system. Hence we know that
the car having a four wheels which has two double wishbone suspension systems at each
wheel (front / rear). Therefore we have four wishbone suspension systems at each wheel for a
car all of them are similar to each other. So we can carry out the analysis for any one of them.
The first step is to split the above system in to half and remove the excess components like
tire, differential, rim etc. By removing all the unnecessary parts from the system it would be
as figure 5.2. The wishbone suspension system consists of rear suspension, spring, wheel hub,
upper control arm and lower control arm.
38
Table : 5.1
39
5.3.1.1 1D Meshing
Two of the dimensions are very large in comparison to third one. X, Y are comparable and Z
is negligible.
Element Type :Thin shell, plate, membrane, plane stress, plane strain, axi-symmetric solid
etc.
Practical Application : Sheet metal parts, plastic components like instrument panel etc.
Skew 75
Jacobean 60
Table 5.2
41
Meshing the components wheel hub, spring, rear suspension, upper control arm and lower
control arm with the above criteria.
42
43
44
Creating 1D Elements :
1D elements are created to combine the two components (straight beams) and to give the
connectivity to the elements at wholes (wagon wheel beams).
M.Tech, Product Design | Jawaharlal Nehru Technological University Ananthapuram, 2011-13.
Creation of Straight Beams :
Measure the radius of the whole where beam is to be created, and create a property of a beam
with that radius. Create a center of the whole along the no. of elements along the whole; join
these points in a indirection.
Measure the surface area of the whole say X, count the no. of node along the whole say Y,
equating X and Y to the area of the circle ( ).
i.e. = X / Y,
From this equation we have to find the radius ‘r’, and create a property of a beam with this
radius. Create a circle center of a whole and join the nodes of the elements in circular path,
translate this wagon wheel beam along the whole.
45
Spring suspension is constrained at one and three degree of freedoms (i.e, Ux, Uz). so that it
may not move in X and Z directions respectively. To achieve valid results boundary
conditions are considered.
For spring constraints are applied on the surface with one and three Degree of freedom i.e,
Ux, Uz = Arrested
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In order to calculate the actual load transfer in the system, a 100N dummy dynamic load is
applied at the wheel hub to test the whole system for accuracy. A test run is carried out to
validate the results. By these results the actual load is calculated, it well defined in upcoming
chapter.
48
PROCESSING
Optimization of any component takes a lot of time and need skilled team to develop a
modified component. It takes nearly eight to fifteen months. During this period the team
investigates the whole system for modifications such as type of material to be changed,
thickness, avoiding excess parts in the components, reducing weight etc.
Due to the time consideration, lack of industrial experience I’m unable to optimize the full
modal. With my exposure to Hypermesh, I concentrated only on optimization of Upper
control arm. It took for me more than four months to optimize the control arm apart from
learning Hypermesh software. To check for the displacement of the elements should be in
first order trias and for optimization the elements are changed to second order trias.
Bluish color represents the non design part (front and rear). This part is meshed with the 3D
elements (tetra mesh). In between these parts i.e, pink and yellow color mesh (2D mesh with
R-Trais) represents the design space. The yellow color forms a medium between the 2D and
3D mesh. The design space is going to optimize the arms for thickness, weight, strength, 49
stress etc.
Previously we applied 100N dummy dynamic load for the system. Repeat the same process
for this system (include modified control arm).
With this 100N force acting on the wheel hub, we have to find out the force distribution at
upper control arm. It is well calculated by the control cards. Control card is used to display
the output forces for the request elements / nodes. The request elements / node are created in
separate sets for both elements / nodes. We selected two node at the upper control arm
(1045060, 1045061).
Node: 1045060
X: 20.43,
Y: 25.41,
Z: 3.35.
Node: 1045061
X: -45.11,
Y: -6.659, 50
Z: -12.07.
1kg = 9.8N
1000kgs = 9800N
Approximately = 10000N.
The force distribution at the given nodes (1045060, 1045061) for 10000 N is calculated as
below.
Node: 1045060
X: 20.43 at 100 N.
X: ? at 10000N.
i.e., X = 2043,
Similarly, Y = 2541,
Z = 335 .
Node: 1045061
X = - 4511,
Y = 6659,
Z = - 12.07.
Now applying these force at nodes 1045060, 1045061 with respect to the X, Y, Z axis
respectively.
Applying these forces at respective nodes run the analysis for varied thickness for design
space for linear static analysis, buckling analysis, modal analysis. These analysis are
performed at varied thickness are discussed in detailed in upcoming chapter. 51
52
ANALYSIS
7.1.1 Linear :
Linear means straight line. σ = ɛ E is equation of straight line (y = m x) passing through
origin."E" Elastic Modulus is slope of the curve & is a constant. In real life after crossing
yield point material follows non liner curve but software follows same straight line.
Component brake into two separate pieces after crossing ultimate stress but software based
analysis never show failure in this fashion. It shows single unbroken part only with red color
zone at the location of failure.
Analyst has to conclude whether the component is safe or fail by comparing the max. Stress
value with yield or ultimate stress.
7.1.2 Static :
There are two conditions for static analysis
1) No variation of force with respect to time (dead weight)
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∑Fx= 0, ∑Mx= 0,
∑Fy= 0, ∑My= 0,
∑Fz= 0, ∑Mz= 0.
The upper control arm is carried linear static analysis at varied thickness of the material at
design space for six iterations from 15mm to 10mm thickness. By applying calculated load
for 10000N in X, Y, Z axis respectively at the given nodes (1045060, 1045061).
In initial volume, displacement of the upper arm is 9.2e5 mm3 and 3.44 mm respectively. This
displacements is higher than their loads. So I reduce the displacement by reducing the volume
of the upper arm.
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Figure : 7.3 Displacement
In before optimization, the stress plots are shown in fig.7.3. This plots to give a value of
amount of stress concentration. Where ever the stresses are too low, that places should reduce
the amount of volume. This reduction of volume to reduce the displacement in previous load
condition. Blue color represents the low stress value and red color is high stress value.
In this stress plots to gave a new ideas for optimization process. Where ever the stress value
is too low that particular area can be reduced.
Tensile force is only on the strips & load carrying places 55
This elongation only affect the life time of the control arm
M.Tech, Product Design | Jawaharlal Nehru Technological University Ananthapuram, 2011-13.
Figure : 7.6 P3 Minor (Compression)
This is the displacement plot about X axis. This value is compare to the previous value
difference are there in the places, because I reduce the material from the previous component.
56
In this plot to explain the overall stress on the material. This stress values are seen in fig. In
strips stresses are too low, but I consider the connectivity of the component with strips and
two wishbones. In two wishbones where ever the stresses are low that particular area the
material can remove. I take a parameters in direct software.
57
61
Classically this was done with a SIMO (single-input, multiple-output) approach, that is, one
excitation point, and then the response is measured at many other points. In the past a
hammer survey, using a fixed accelerometer and a roving hammer as excitation, gave a MISO
(multiple-input, single-output) analysis, which is mathematically identical to SIMO, due to
the principle of reciprocity. In recent years MIMO (multi-input, multiple-output) has become
more practical, where partial coherence analysis identifies which part of the response comes
from which excitation source.
Typical excitation signals can be classed as impulse, broadband, spite sine, chirp, and
possibly others. Each has its own advantages and disadvantages. The analysis of the signals
typically relies on Fourier analysis. The resulting transfer function will show one or more
resonances, whose characteristic mass, frequency and damping can be estimated from the
measurements.
It is also possible to test a physical object to determine its natural frequencies and mode
shapes. This is called an Experimental Modal Analysis. The results of the physical test can be
used to calibrate a finite element model to determine if the underlying assumptions made Ire
correct (for example, correct material properties and boundary conditions are used).
Before starting the analysis we have to select EIGRL force for modal analysis, we have to
choose minimum three roots to find the effect of stress completely on the arms. So we choose
five roots for the analysis for varied thickness of design space.
Contour plots of modal analysis for 15mm thickness.
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65
POST-PROCESSING
8.1 Comparison of results - Linear Static Analysis :
Thickness ‘mm’ 15 14 13 12 11 10
Von-Misses 42 44 47 50 54 59
stress
P1Major
(Tension) 42 45 48 50 54 59
P2 Minor
(Compression) 6.3 6.5 7.3 8.4 9.6 11
Table :8.1
Thickness ‘mm’ 15 14 13 12 11 10
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Thickness ‘mm’ 15 14 13 12 11 10
Mode 1 in ‘Hz’ 80 81 28 85 85 87
15 924668.4 7.305e-3
14 863023.84 6.818e-3
13 801379.28 6.331e-3
12 739734.72 5.844e-3
11 678090.16 5.357e-3
10 616445.6 4.87e-3
Table : 8.4
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According to the Automotive Industry Standards Committee (AISC) the factor of safety for
automobile components is specified as 3.5 and the factor of safety for the proposed upper
control arm of suspension system is 3.49 is very nearer to the desired value, here all the
stress, deformation and factor of safety of the proposed upper control arm is within the limit
of permissible values, hence the design is considered to be optimum.
Each car having four wheels. It means there are four (4 No’s) uppercontol arms
= Rs 145× 4
= Rs 580 per car.
Average cars roll out for market = 1 lakh cars
= 4 lakh upper control arms
= 4 00 000 × 580
= 23 Crore 20 Lakhs Savings.
Overall cost savings per annum on all the cars = 1 Lakh × 22, 922
Total Savings per annum through this project = Rs 229 Crores 22 Lakhs.
In comparison of features, displacements are reduced, and also compare the stress
plots, stresses are increased
So that component has low displacement & high stress can increase the life time of
the component.
If the life time can increase, usage of the component level can increase.
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Table : 9.1
The weight of the existing upper control is found to be 7.25 Kg and after design
optimization the weight of the proposed upper control arm has come to a weight of
4.83 Kg. The percentage of weight reduction is 39.5%.
As the factor of safety for the proposed upper control arm subjected to loading is 3.49
which is desired value, the design is optimum.
Also, as the Von-Mises stress obtained in upper control arm is found to be 231.552
N/mm2 which is within the limits of permissible yield strength of 250 N/mm 2, the
design is acceptable.
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6. Ted Belytschko, Wing K Liu, Brian Moran: Non-linear Finite elements for Continua
and Structures, John Wiley and Sons.
7. W. C. Young, R. G. Budynas : Roark's Formulas for Stress and Strain, 7th Edition,
McGraw Hill.
8. R.D.Cook, D.S. Malkus M. E. Plesha: Concept & applications of Finite Element
Analysis, 3rd Edition John Wiley & Sons.
10. J. S. Rao, K.Gupta :The Theory & Practice of Mechanical Vibrations 5Th Edition,
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11. Kewal Pujara: Vibration & Noise For Engineers 4Th Edition – Dhanpat Rai & Sons.
12. Erwin kreyszig : Advanced Engineering Mathematics, 5Th Edition – Dhanpat Rai &
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13. V. Adams & A. Askenazi: Building Better Products with Finite Element Analysis,
Onward Press.
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