DESIGN AND ANALYSIS OF SUSPENSION SYSTEM OF · PDF fileDouble wishbone suspension system is selected and is designed in ... Front double wishbone unequal parallel arm ... Design of

© April 2017 | IJIRT | Volume 3 Issue 11 | ISSN: 2349-6002

IJIRT 144401 INTERNATIONAL JOURNAL OF INNOVATIVE RESEARCH IN TECHNOLOGY 134

DESIGN AND ANALYSIS OF SUSPENSION SYSTEM

OF AN OFF ROAD VEHICLE (ALL TERRAIN

VEHICLE)

Manishkumar Manjhi1, Shaktiprasanna Khadanga2, Bibhutibhusan Sahoo3, SusarthakRath4,

Karankumar Guru 5 and P. Murarji6

1,3,4,5,6Student, Mechanical Engineering Department, Gandhi Institute Of Engineering And Technology,

Gunupur, Odisha, India 2Asst. Professor , Mechanical Engineering Department, Gandhi Institute Of Engineering And

Technology, Gunupur, Odisha, India

Abstract—An ATV is the vehicle which is designed to

move through all terrains. We are using this vehicle for

various range of purposes such as military purpose,

rescue purpose during natural calamities and also for

forest inspections. [1] Suspension system of this vehicle

should be strong enough so that it will give better ride

quality and maximum comfort to the driver. Double

wishbone suspension system is selected and is designed in

LSA (Lotus Suspension Analysis).After designing the

hard points are received and using them A-arms are

designed by using SOLIDWORKS and CATIA software

and after that we selected the material to fabricate it but

before fabrication we have analysed the various stresses

acting upon it by ANSYS. We have also designed front

and rear uprights and analysed it by using ANSYS. This

project aims at selecting, analysing and fabricating a

suspension system of ATV which will capable of handling

at rough terrains.

Index Terms—Camber,Castor,Double Wishbone

Suspension System, Roll Centre Height,Toe,Track

width,Upright,Wheelbase.

I. INTRODUCTION

Suspension system is one of the major component of

the vehicle which is used to have a maximum traction

effort in between road and tyres and to provide

maximum possible comfort to the driver. The contact

between the road and tyres are maintained due to the

load applied by the vehicle which acts through the

tyres and suspension system. We have to design by

keeping 2 aspects in our mind:

1. Uneven surface of roads.

2. Variations in the load.

Road irregularities includes the big hills and small

uneven surfaces which may be termed as high

frequency (hills) and low frequency (uneven

surfaces).Variations in loads are due to various aspects

like load during cornering, load during braking, load

during acceleration [2]. So to sustain in these cases we

must have reliable suspension system which should be

soft for giving comfort to the driver and hard for

carrying uneven loads while travelling in the hills and

mountains.

Suspension system reduces [3] reaction force generated

due to obstructions on the path of the vehicle. This

reaction force’s magnitude is directly proportional to

the unsprung mass of the vehicle. With higher sprung

to unsprung weight ratio we can achieve more

reduction of reaction force effecting both vehicle and

the occupants and can also enhance vehicle control

ability.So suspension system is mainly divided into 2

categories:Dependent Suspension System: Here in this

suspension system the movement of one wheel

depends upon another wheel.Independent Suspension

System:Here in this suspension system the movement

of one wheel does not depends upon another wheel.

Here each wheel is independent of each other.

So we have decided to choose Double Wishbone

System as per our use of the vehicle. Double wishbone

suspension system consist of two a-arms (upper

wishbone and lower wishbone) usually of different

length along with a spring and a damper.This type of

suspension system provides negative camber at the

time of ride and it has[4] an excessive load bearing

capacity. It also provides better stability and roll

height.



II. DESIGN METHODOLGY

Before designing the suspension system of vehicle we

have concentrate upon some of the basic parameters of

the vehicle required for it.So the basic parameters are:

1. Wheelbase:60 inch.

2. Track Width:Front-54 inch,

Rear-50 inch

3. Tire Radius:12 inch

4. Tire Width:8 inch

5. Sprung Mass:180 kg

6. Unsprung Mass:80 kg

So by using these parameters we started the process of

designing the[5] suspension system of the vehicle. We

have selected the LSA (Lotus Suspension Analysis)

software to design it.

2.1 LOTUS Suspension Analysis:

LOTUS suspension analysis tool is used for initial

outline of the vehicle. 3D models can be created and

modified in LOTUS Suspension Analysis (LSA).

Using LSA Hard points are drawn and graphical and

numerical [6]values can be found out. This modelling

approach allows user to make their own suspension

models. The changes in camber angle, toe angle can be

displayed graphically against motions like roll motion,

bump motion, steering motion. Several parameters are

considered to get the hard points of the suspension

system like damping ratio, sprung and un-sprung

weight, spring rate, camber angle, caster angle, roll

centre, wheelbase, track width, toe angle, ground

clearance.

So before designing in LSA we have design

considerations:

Kingpin and caster angle are kept in such a way

that they can compensate each others camber gain, by

providing there individual function.

A positive king pin angle is kept to help in

steering the vehicle.

Roll centre below CG to avoid jacking force.

Front ride frequency is greater than rear.

Roll axis inclined towards front to give

understeer characteristic.

Front double wishbone unequal parallel arm to

have better traction during cornering.

We have taken Damper to lower wishbone for the front

suspension and damper to upper wishbone in rear

suspension system.We have design by using[7] these

parameters and also by checking various properties

such asroll motion, bump motion, steering motion.

These properties are controlled by controlling the

camber,caster, toe ,kingpin angle etc.So after

designing we get the results as:

Numerical value:

Table1: Numerical results

Camber angle( Kerb Weight

&Suspension Travel)

0 deg 1.73deg

Caster angle 0.13 deg

King pin angle 0.78deg

Scrub radius (mm) 40.477

Toe In & Toe Out 0deg 0deg

Fig1: Roll Axis is inclined toward the front.

Fig2: Roll Centre below CG.



Graphical Representation:

After designing in the LSA we hardpoints of the

suspension system. [8]We will use these hardpoints as

the coordinates for designing the wishbones.

So, for designing the Front Wishbones the coordinates

are:

Fig7: Front Suspension Coordinates

And for designing the the Rear Wishbones the

coordinates are:

Fig8: Rear Suspension Coordinates

Fig3:Graph between

Castor Vs Travel

Fig5:Graph between

Camber Vs Travel

Fig4:Graph betweenToe

Angle Vs Travel

Fig6:Graph between

Spring Travel Vs Wheel Travel



2.2design Of Wishbones:

Design of the suspension was carried out in Computer

Aided Designing (CAD) using CATIA deigning

softwareV5R21 and SOLIDWORKS for designing

purpose.

Design of wishbones[9] is the major step to construct a

suspension system. Initially, for designing we have

coordinates from LSA.

2.2.1Front Wishbones:

Double wishbone suspension system of unequal length

and parallel was implemented for Front suspension.

We finalize the shape of wishbone to be A/V as it can

distribute stresses over the members effectively.

Upper wishbone is shorter than lower wishbone. The

advantage of having different lengths is that when the

vehicle takes a turn a negative camber is induced

which increases the stability.[10] Often this

arrangement is titled as SLA (Short Long Arm). As we

are having damper to lower wishbone in front side so

the lower wishbone will be of A shape and the front

upper wishbone will of V shape. As we have caster

angle 0.13 deg which makes our front suspension

unequal and parallel. We will mount the spring in the

lower wishbone which will be tilted towards the rear

side.

Fig9:Front Lower A-Arm

Fig10:Front Upper Arm

2.2.2Rear Suspension system:

It consists of equal A-arms and parallel arm design.

Independent equal A-arms are widely accepted as

camber changes can be easily eliminated. One end is

attached to the chassis and other end is attached to the

knuckle. A-arm provides large amount of travel and

mostly equal the front suspension system. At rear side

the camber angle and caster and also the toe angle will

the zero. For making toe angle zero we are connecting

a zero toe rod.

As we are having damper to upper wishbone in rear

side so the upper wishbone will be of A shape and the

rear lower wishbone will of V shape.As we have

caster and[11] camber angle 0deg which makes our

front suspension equal and parallel. We will mount

the spring in the upper wishbone which will be tilted

towards the front side.

Fig11: Rear Upper A-Arm



Fig12: Rear Lower Arm

So in this way we had designed both the

wishbones.After designing of the wishbones we had

done the material selection by looking into various

parameters such as ultimate strength, yield strength

etc. The material selection was also based upon the

material strength to bear the loads acting in the

dynamic [12]condition. So the material considered

according to the market availability was AISI-4130 as

it was lighter in weight along with optimum cost.

Material selected-AISI 4130

Outer diameter-25.4mm

Inner diameter-19.8mm

Physical Properties Of Aisi 4130

Ultimate strength:560MPa

Carbon content: 0.28

Yield strength:460MPa

Elongation at break (in 50mm): 21.50%

Modulus of elasticity: 210GPa

Poisson’s ratio:0.3

Bulk modulus:140GPa

Density: 7.85 gm/cm3

2.3 Upright Design:

Upright is design by CATIA and SOLIDWORKS

software by using the proper tire dimensions. It is

designed in such a way that it could hold the upper and

lower pivot points of the a-arms and the output axle

long with the hub and brake callipers without any[13]

difficulties .After the designing it is validated using the

CATIA FEA package. After this it is tested by

assembling all the remaining parts of the suspension

system.

Fig13:Front Upright

III. ANALYSIS

After designing is over in CATIA [14]it is imported to

ANSYS simulation software (Computer Aided

Engineering). Analysis of suspension is done by using

ANSYS software. Several types of thermal analysis,

structural analysis can be made possible using ANSYS

software. Here we are conducting structural analysis

to define the boundary conditions and to determine the

stresses and deflection developed by applying various

loads.

For analyzing the whole system some basic

calculations are used [15]to calculate the values of

various loads acting on it. A certain amount of force

will be given in order to see the various deformations

which are going to be held during simulation. So to

check this we are using the FEA software ANSYS to

view these deformations.

3.1Analysis of wishbone:

For analysis of the wishbones a 3G newton amount of

force is given to check the strength of the design of the

wishbones. By this we calculated [16]the maximum

possible deformation and maximum stress developed

in the arms in the impact load conditions.

Fig14: Rear Upright



Fig15: Stress Analysis of A-arms

3.2Upright Analysis:

The front and rear upright are analysed by FEA

analysis software ANSYS. The upright will give

support to the bearings of the hub which ultimately

allows[17] the wheels to rotate.The FEA analysis is

done by applying 2000N which gives some amount of

red zones on the upright.

So to harden the upright we fabricated it by using

aluminium alloy to give strength of that it can sustain

the forces acting on it. The front upright is of material

Aluminium alloy 7560 and rear upright is fabricated

by using Aluminium alloy 6061-T6.[18]Both the

uprights are having different material because of their

different design.

IV. RESULTS

After Manufacturing the ATV various tests are.Those

tests includes both static and dynamic tests. The

following results are received from static conditions:

1. Centre of Gravity Height: 18 inch

2. Ground Clearance:13 inch

3. Roll Centre Height

1. Front:230mm

2. Rear:260 mm

Dynamic results are received by testing the vehicle in

various terrains like mud, hills etc. We can further

modify the suspension system of the vehicle by using

trailing[19] and semi-trailing arm at rear side in the

spring will be mounted on knuckle and firewall.

Trailing arm and Semi- Trailing arms will be mounted

on the knuckle and the base of the chassis.

V. CONCLUSION

The paper describes about designing and analysing

suspension of an All Terrain Vehicle (ATV) and their

integration in the whole vehicle. The ATV has been

designed and analysed based on the facts of vehicle

dynamics. The primary objective of this paper was to

identify the design parameters of a vehicle with a

proper study of vehicle dynamics. This paper also

helps us to study and analyse the procedure of vehicle

suspension designing and to identify the performance

affecting parameters. It also helps to understand and

overcome the theoretical difficulties of vehicle

design.

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DESIGN AND ANALYSIS OF SUSPENSION SYSTEM OF · PDF fileDouble wishbone suspension system is selected and is designed in ... Front double wishbone unequal parallel arm ... Design of