International Research Journal of Engineering and Technology (IRJET)
e-ISSN: 2395-0056
Volume: 12 Issue: 05 | May 2025
p-ISSN: 2395-0072
www.irjet.net
Design and Development of FSAE Electric Vehicle Suspension System Pratik Chavan1, Omkar Chowdhary2, Pratham Vaity3, Rohit Kamble4, Anuj Mandlik5 1Student, Department of Mechanical Engineering, Terna Engineering College, Navi Mumbai, India
2Student, Department of Mechanical Engineering, Terna Engineering College, Navi Mumbai, India 3Student, Department of Mechanical Engineering, Terna Engineering College, Navi Mumbai, India
4Student, Department of Mechanical Engineering, Terna Engineering College, Navi Mumbai, India 5Student, Department of Mechanical Engineering, Terna Engineering College, Navi Mumbai, India ---------------------------------------------------------------------***---------------------------------------------------------------------
Abstract – The paper outlines the design methodology and
motorsports, this system becomes important as it sets the framework for the vehicle's behaviour in turning and going over the curbs. A perfect suspension setup enhances a vehicle's on-track performance.
development process of a double wishbone suspension intended for a Formula Student EV. The system was tuned for handling, durability, and compliance with competition standards. CAD modeling, kinematic analysis, and FEA were conducted to ensure geometry and strength validation. To optimize packaging constraints and enable finer suspension tuning, a bell-crank layout actuated via pushrods was integrated into the system. Load cases were examined to ascertain reliability under race conditions. The ultimate system was constructed and tested, showing satisfactory performance and structural integrity.
1.1 Background Earlier, car suspension systems came from simple designs used in carts pulled by oxen. Back then, they used iron chains and later leather straps to help soften the ride. When cars started moving on their own, new metalworking techniques were needed. This led to better spring suspensions that made rides smoother. In the 19th century, Obadiah Elliott patented something really important: strong steel leaf springs that could hold up vehicle bodies right on the axles [2]. By 1904, we saw the first signs of what we know today as modern car suspensions. Then, in 1906, things got even better with the addition of front coil springs on flexible axles. Leaf has a long history, dating back to their use in carriages around 1804. People liked them because they were cheap and could handle different loads by changing their shape. And even though coil springs were first thought of way back in 1763, car makers chose leaf springs for how practical & versatile they were in those early vehicle designs.
Key Words: Suspension System, Double Wishbone Suspension, Finite Element Analysis (FEA), Vehicle Dynamics, Vehicle Performance, Suspension Optimization.
1.INTRODUCTION In every automobile, the suspension system functions as a fundamental element establishing the mechanical connection between the chassis and the wheels. Moreover, it operates as the backbone element in vehicle dynamics by regulating wheel trajectories and maintaining optimal camber throughout dynamic manoeuvres by transferring shocks and impacts of tires and evenly distributing them throughout the mainframe. This is very critical in the realm of elite motorsport systems like Formula One, Formula Endurance, etc. Also, the Formula Student race cars, which are essentially scaled-down replicas of Formula One cars, are designed and built by university students for competitions such as Formula Imperial and Supra SAE. Evolving suspension design holds elevated significance, offering effortless adjustability, mass efficiency, and razor-sharp control over wheel trajectory [1]. Performance automobiles frequently employ the double wishbone suspension setup that provides better performance. Double wishbone can have two different options: push-rod or pull-rod actuated systems; either of them may be implemented depending on the needs and objectives of the vehicle. Some components of suspension structural units are springs, tires, dampers, shock absorbers, A-control arms, and wheel uprights. They work in conjunction with the vehicle frame to control the forces exerted by the road uncertainties. Also, in
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Impact Factor value: 8.315
2. LITERATURE SURVEY A detailed simulation strategy was employed to determine precise hardpoint locations, optimizing suspension geometry for responsive vehicle dynamics [3]. Follow-up validations ensured that the configuration balanced structural packaging with performance objectives. Suspension geometry modifications were implemented to ensure vehicle balance during transient manoeuvres like turning, braking, and accelerating [4]. Accuracy in caster-camber alignment resulted in correlated lateral force behavior and enhanced trajectory consistency during maneuvers. Ontrack feedback reported substantial improvements in responsiveness and stability. A sequential process was employed to incorporate push-rod actuation in the front suspension so that it is compatible with A-arm location and spring-damper orientation [5]. The layout minimized packaging and facilitated controlled force
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