Analyzing suspension upright of a Formula Society of Automotive Engineers style vehicle.

Abstract

This project was aimed at modelling the stress and deformation profile of a 6061-T6 aluminium suspension upright of a formula society of automotive engineers style vehicle with a double wishbone suspension under the loading conditions of a 1.5G corner. With these results, it would need to be determined whether the design is fit for use. Using remote displacement boundary conditions for the upper and lower wishbone connections and the control arm connection with a remote force at the centre of the wheel patch acting on the bearing surfaces the maximum stress, overall stress profile and maximum deformation of the upright was calculated. These results after, undertaking a verification and validation study, were a maximum equivalent von-Mises stress of 87.358MPa and a maximum bearing surface deflection of 0.21 mm. The maximum von-Mises stress calculated was less than the fatigue limit of 90MPa signalling infinite life and also less than the yield stress of 240MPa signalling a safe design. Verification and validation techniques were used to ensure the final result was accurate and reflected the real – life system. Structural error was used to verify the results where it was found that maximum structural error in the upright was 0.052mJ and at the location of maximum stress was between 0.0058-1.0782e-8 mJ. Validation of the model was achieved by comparing the reaction forces calculated in ANSYS to theoretical values and was found that the magnitudes were within 2.5% of the theoretical values, thus the model was considered valid.