Imperial Journal of Interdisciplinary Research (IJIR)
Vol-2, Issue-9, 2016
ISSN: 2454-1362, http://www.onlinejournal.in
Design and Modal Analysis of Lower Wishbone
Suspension Arm Using FE Approach
Mr. Prashanthasamy R.M.Ta, Dr. Sathishab, Mr. Imran Ali M.Rc &
Mr. Jnanesh. K d
a
Research Scholar, Mechanical Engineering, S.I.E.T, Tumkur, Karnataka, India.
H.O.D and Professor, Mechanical Engineering, S.I.E.T, Tumkur, Karnataka, India.
c
Assistant Professor, Mechanical Engineering, H.M.S.I.T, Tumkur, Karnataka, India.
d
Research Engineer at Think and Ink Education and Research Foundation Bangalore,
Karnataka, India
b
Abstract: In automobile industries wishbone arm is
major component in this suspension system which
is of independent suspension. The major function of
arm is to maintain smooth suspension condition.
The arms are usually upper and lower arm. The
loads will be acting more on lower arm than upper
arm because of its position. These load conditions
on lower arm leads to maximum bending. Presently
in the most of the automobiles industries are using
suspension arm of hallow and idled of steel AISI
1040 material. Hence in this thesis the study is
made on existing design with aluminum alloy. The
3D model will be generated by Catia V5, the FE
model will be generated by HyperMesh and the
static and dynamic analysis will be conducted by
Abaqus.
INTRODUCTION
The postponement structure is a prominent
amongst the most critical segments of vehicle,
which specifically influences the wellbeing,
execution, clamor level and style of it. The vehicle
suspension framework is in charge of driving
solace and security as the rearrangement conveys
the automobile-body and transmits all powers
between corpse and street. Emphatically, with a
exact end goal to impact these properties, semidynamic segments are presented, which empower
the deferral scaffold to adjust different driving
conditions. From a configuration perspective, there
are two principle classes of unsettling influences on
a truck to be definite the street and burden
aggravations.
LITERATURE SURVEY
[2] This anticipate presents the
advancement of hearty configuration of lower
suspension arm utilizing stochastic improvement.
The quality of the outline examine by limited
component programming. The basic model of the
lesser postponement arm was mode by utilizing the
strong works. The imperfect component replica and
assessment were executed using the partial
constituent investigation code. The direct versatile
Imperial Journal of Interdisciplinary Research (IJIR)
examination was performed utilizing NASTRAN
codes. TET10 and TET4 network has been utilized
as a part of the anxiety inspection and the most
noteworthy Von Mises anxiety of TET10 has been
chosen for the hearty design parameter.The
improvement of Powerful outline was completed
utilizing the Monte Carlo approach, which all the
streamlining parameter for the configuration has
been
advanced
in
Strong
arrangement
programming. The changes from the Stochastic
Outline Change (SDI) are acquired. The outline
capacity to bear more weight with lower
anticipated anxiety is distinguished through the
SDI procedure. A minor thickness and modulus of
versatility of material can be reexamined with a
specific end goal to streamline the delineate. [3] is
a strategy for idea choice utilizing a scoring lattice
called the Pugh Grid. It is executed by building up
an assessment group, and setting up a lattice of
estimation criteria versus elective epitomes. This is
the scoring framework which is a type of
prioritization lattice. For the most part, the choices
are attain in respect to criteria utilizing a typical
methodology (one image for superior to, another
for unbiased, and another for more regrettable than
gauge). These get changed over into achieves and
consolidated in the scaffold to yield scores for
every alternative. [7] Palma, in this study, a
disappointment investigation of a longitudinal
stringer of a model vehicle has been done.
Disappointment occurred at the guards obsession
purposes of the vehicle suspension amid toughness
tests. Break was made and has developed creating
crack of the segment. Stress investigation was
performed utilizing limited component strategy. A
support model to take care of the issue was
proposed. Test semi static and sturdiness tests were
completed and disappointments were no more
watched.
OBJECTIVES & METHODOLOGY
3.1 OBJECTIVE:
1. To prepare the existing design of
wishbone suspension arm.
Page 858
Imperial Journal of Interdisciplinary Research (IJIR)
Vol-2, Issue-9, 2016
ISSN: 2454-1362, http://www.onlinejournal.in
2.
To conduct linear static and dynamic
analysis for the existing design.
3. To create an optimized design by
conducting
geometric
material
optimization.
3.2 METHODOLOGY:
1. Existing design of the wishbone
suspension arm is studied.
2. 3d CAD model of the design will be
created.
3. FE Model of the design will be created.
4. Analysis under Static and modal
conditions will be done and the behaviour
of component will be estimated.
5. Based on the results obtained in analysis
the design will be optimized in different
stages.
6. Finalized design will be presented.
Table: 4.1
MATERIAL PROPERTIES OF AISI 1040:
YOUNGS MODULUS
210 GPa
POISSONS RATIO
0.30
DENSITY
7.845 e-3 g/mm3
YIELD STRESS
410 MPa
BOUNDARY CONDITIONS FOR LINEAR
STATIC ANALYSIS:
One end is constrained in all the directions and
other end is applied a load of 5000 N for this
Distributed pressure is applied.
Load, F = 5000 N
Area of applied pressure, A = 7520 mm2
Force
5000
Therefore, Pressure, 𝑃 =
=
= 0.664 MPa
Area
7520
Hence, the pressure is applied of 0.664 MPa
RESULTS AND DISCUSSIONS
4.1 DESIGN AND ANALYSIS OF EXISTING
WISHBONE ARM:
4.1.1 2-D DRAWING OF EXISTING
WISHBONE ARM:
Fig: 4.5 Boundary Conditions
4.4 RESULTS OF LINEAR STATIC
ANALYSIS OF EXISTING DESIGN:
4.4.1 Von-Mises Stress:
4.4.2 DEFORMATION PLOT:
Fig4.1: 2D drawing of Existing Wishbone Arm
4.1.2 3-D MODEL OF EXISTING WISHBONE
ARM: 4.2 FINITE ELEMENT MODEL OF
EXISTING WISHBONE ARM:
Fig: 4.6 Von-Mises Stress Plot
Fig: 4.7 Deformation Plot
Maximum Stress = 218.2 MPa
Maximum Deformation = 2.062 mm
4.5 MODAL ANALYSIS OF EXISTING
DESIGN FOR AISI 1040:
Deformation plots for different Natural
Frequencies:
Fig4.2: CAD Model of Existing Wishbone Arm
Fig: 4.3 Finite Element Model Existing Wishbone
Arm
4.3 ANALYSIS WITH AISI 1040
Imperial Journal of Interdisciplinary Research (IJIR)
Page 859
Imperial Journal of Interdisciplinary Research (IJIR)
Vol-2, Issue-9, 2016
ISSN: 2454-1362, http://www.onlinejournal.in
4.9 MODAL ANALYSIS FOR EXISTING
DESIGN ALUMINIUM ALLOY 6061:
Deformation plots for different Natural
Frequencies:
Table: 4.2 Frequency Modes of Existing Design
Modes
Frequeinces
Mode 1
0.2418
Mode 2
0.8247
Mode 3
0.9216
Mode 4
1.3160
Mode 5
2.0980
4.7 ANALYSIS WITH ALUMINIUM ALLOY
Table: 4.3 MATERIAL PROPERTIES OF
ALUMINIUM ALLOY:
YOUNGS MODULUS
68.3 GPa
POISSONS RATIO
DENSITY
YIELD STRESS
0.33
2.6898 e-3 g/mm3
210 MPa
BOUNDARY CONDITIONS FOR LINEAR
STATIC ANALYSIS:
One end is constrained in all the directions and
other end is applied a load of 5000 N for this
Distributed pressure is applied.
Load, F = 5000 N
Area of applied pressure, A = 7520 mm2
Force
5000
Therefore, Pressure, 𝑃 =
=
= 0.664 MPa
Area
7520
Hence, the pressure is applied of 0.664 MPa
Table: 4.4 Frequency Modes of Existing Design
with Aluminum Alloy
MODES
FREQUIENCES (Hz)
MODE 1
0.2351
MODE 2
0.8109
MODE 3
0.8935
MODE 4
1.2800
MODE 5
2.0496
Table: 4.5: MATERIAL PROPERTIES OF
Von-Mises Stress and Maximum Deformation
Material
Fig: 4.15 Boundary Conditions
4.8 RESULTS OF LINEAR STATIC
ANALYSIS OF EXISTING DESIGN:
4.8.1 Von-Mises Stress:
4.8.2 DEFORMATION PLOT
Von-Mises
Stress
(MPa)
218.2
6.334
Maximum
Deformation
(mm)
2.062
215.9
AISI 1040
Aluminium
Alloy
4.11 DESIGN AND ANALYSIS OF NEW
DESIGN-1 WISHBONE ARM:
4.11.1 2-D DRAWING OF NEW DESIGN-1
WISHBONE ARM:
Fig: 4.17 Von-Mises Stress Plot
Fig: 4.19 Deformation Plot
Maximum Stress = 215.9 MPa
Maximum Deformation = 6.334 mm
Imperial Journal of Interdisciplinary Research (IJIR)
Page 860
Imperial Journal of Interdisciplinary Research (IJIR)
Vol-2, Issue-9, 2016
ISSN: 2454-1362, http://www.onlinejournal.in
4.13 RESULTS OF LINEAR STATIC
ANALYSIS OF NEW DESIGN:
4.13.1 Von-Mises Stress:
4.13.2 DEFORMATION PLOT:
Fig: 4.27 2-d drawing of new design-1 wishbone
arm:
4.11.2 3-D Model of New Design-1 Wishbone Arm
4.12 Finite Element Model of Existing Wishbone
Arm:
Fig: 4.32 Von-Mises Stress Plot
Fig: 4.34 Deformation Plot
Maximum Stress = 63.67 MPa
Maximum Deformation = 1.715 mm
4.13.3 MODAL ANALYSIS OF EXISTING
DESIGN FOR ALUMINIUM 6061:
4.13.4 Deformation plots for different Natural
Frequencies:
Fig: 4.28 CAD Model of New Design-1
Fig: 4.29 Finite Element Model of New
Wishbone Arm
Design-1 Wishbone Arm
ANALYSIS WITH ALUMINIUM 6061
Table: 4.6 MATERIAL PROPERTIES OF AISI
1040:
YOUNGS MODULUS
68.3 GPa
POISSONS RATIO
0.33
DENSITY
2.6898 e-3 g/mm3
YIELD STRESS
210 MPa
BOUNDARY CONDITIONS FOR LINEAR
STATIC ANALYSIS:
One end is constrained in all the directions and
other end is applied a load of 5000 N for this
Distributed pressure is applied.
Load, F = 5000 N
Area of applied pressure, A = 7520 mm2
Force
5000
Therefore, Pressure, 𝑃 =
=
= 0.664 MPa
Area
7520
Hence, the pressure is applied of 0.664 MPa
Imperial Journal of Interdisciplinary Research (IJIR)
Fig: 4.40 Mode-4 plot
Fig: 4.41
Mode-5 plot
Table: 4.7 Frequency Modes of New Design-1
Wishbone Arm
MODES
FREQUEINCES
MODE 1
0.2285
MODE 2
0.9817
MODE 3
1.0175
MODE 4
1.5512
MODE 5
2.3332
Table: 4.8 Material values for von-mises stress
and max-deformation.
Material
Von-Mises
MaxStress
Deformation(mm)
(MPa)
AISI 1040
218
2.062
(Existing
Design)
Aluminium
220
6.3
(Existing
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Imperial Journal of Interdisciplinary Research (IJIR)
Vol-2, Issue-9, 2016
ISSN: 2454-1362, http://www.onlinejournal.in
Design)
Aluminium
(New Design1)
64
1.7
4.16 RESULTS OF LINEAR STATIC
ANALYSIS OF NEW DESIGN:
4.16.1 Von-Mises Stress:
4.16.2 DEFORMATION PLOT:
4.14 DESIGN AND ANALYSIS OF NEW
DESIGN-2 WISHBONE ARM:
Fig: 4.46 Von-Mises Stress Plot
Deformation Plot
Maximum Stress = 74.56 MPa
Deformation = 2.167 mm
Fig: 4.42 2-d drawing of existing wishbone arm:
4.14.1 3-D MODEL OF EXISTING WISHBONE
ARM: 4.14.2 FINITE ELEMENT MODEL OF
EXISTING WISHBONE ARM:
Fig: 4.43 CAD Model of Existing Wishbone arm
Fig: 4.44 Finite Element Model Existing Wishbone
Arm
4.15 ANALYSIS WITH ALUMINIUM 6061
Table: 4.9 MATERIAL PROPERTIES OF AISI
1040:
YOUNGS MODULUS
68.3 GPa
POISSONS RATIO
0.33
DENSITY
2.6898 e-3 g/mm3
YIELD STRESS
210 MPa
BOUNDARY CONDITIONS FOR LINEAR
STATIC ANALYSIS:
One end is constrained in all the directions and
other end is applied a load of 5000 N for this
Distributed pressure is applied.
Load, F = 5000 N
Area of applied pressure, A = 7520 mm2
Force
5000
Therefore, Pressure, 𝑃 =
=
= 0.664 MPa
Area
7520
Hence, the pressure is applied of 0.664 MPa
Imperial Journal of Interdisciplinary Research (IJIR)
Fig: 4.48
Maximum
MODAL ANALYSIS OF EXISTING DESIGN
FOR ALUMINIUM 6061:
4.16.3 Deformation plots for different Natural
Frequencies:
Table 4.10: Frequency Modes of Existing
Design
Modes
Frequeinces (Hz)
Mode 1
0.2184
Mode 2
0.9928
Mode 3
1.0294
Mode 4
1.5110
Mode 5
1.9577
Table 4.11: Material properties of von-mises
stresses and deformation.
Material
Von-mises
Deformation
stresses
(mm)
(MPa)
AISI(ED)
218
2.062
AL(ED)
220
6.3
ND1
63.67
1.715
ND2
74.56
2.167
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Imperial Journal of Interdisciplinary Research (IJIR)
Vol-2, Issue-9, 2016
ISSN: 2454-1362, http://www.onlinejournal.in
CONCLUSION
The main objective of this project is to
develop the model and perform the static and
model analysis of wishbone suspension arm.
From the above analysis it can be concluded that
1. The stresses and deformation is maximum
in the existing design with AISI 1040 of
218 MPa and 2.062 mm respectively.
2. The stresses and deformation for the
existing design with aluminium alloy is
almost maximum compare to AISI 1040.
3. In the existing design of wishbone
suspension arm is completely hallow and
it is welded joint, due to which there is a
chances of fracture at the welded joints.
4. New design has been developed to reduce
stresses and deformation existing in the
current design with aluminium alloy
which is completely moulded.
5. In the new design 1 and new design 2 of
aluminium alloy, the stresses are almost
reduced to 30% compare to existing
design.
6. The deformation in the new design 1 and
new design 2 is almost reduced to 10%
existing design.
7. Finally it can be concluded that from the FE
analysis the new design 1 and new design
2 can be replaced with aluminium alloy
existing design with AISI 1040 for
wishbone suspension arm.
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