Analyzing Car Suspension System using Finite

Element Analysis
Graduation Project Submitted
By

Mahmoud SHALABY
Edwar BARSOUM

Under the supervision of

Assistant Professor Dr. Adham Ragab
 Summary
Project scope and goals.
FEA.
Torsion beam suspension system.
Methodology.
Future work.
Torsion beam suspension
 Introduction
The suspension system in automotive play a vital role
in its stability.
Torsion beam suspension is used usually as rear wheel
suspension systems of a FF-type vehicle.
Consists of two trailing arms mounted to the body
with bushings and a single torsion beam that connects
these arms together.
 Goals
• Calculating maximum allowable stresses.
• Fatigue life.
• Calculating the expected loads on the suspension
system.
• Model solution.
• Post processing.
 A comparison between Experimental
Road Data and FEA Data for the Lower
Suspension Arm done by
Nawar A. Al-Asady
S. Abdullah
A.K. Ariffin
S.M. Beden
M.M. Rahman
Department of Mechanical and Materials Engineering
UKM,43600 UKM Bangi
Selangor,Malysia
Experimental road data
Finite Element Model
Strain distribution
Fatigue life distribution
Damage after applying SAESUS
and experimental loading
Operations of life path prediction
 Flow of FEA

How to achieve accuracy?

 Suspension fatigue analysis
Fatigue life prediction play a big role in the design of
components and its manufacturing, automotive
industries seeks to reduce costs and manufacturing
time for high quality levels.
Stress analysis required.
Importance of car suspension.
Durability play a big role.
Calculating fatigue life.
Materials and fabrications.
 FEA
History of FEA.
How does it work
 Creating a finite element model using ANSYS
 Analysis type
 Meshing
 Boundary conditions
 Solution
Accuracy of results.
FEA save time and cost
Creating a Finite Element model.

Preprocessing phase

Applying boundary conditions,

loads, and the Solution

Post processing phase (Results of

FEM)
Methodology
 Car suspension
Construction
Part design
Manufacturing
Dimensions
 Construction
Spring
Shock absorber (damper)
Linkage (mechanism)
Wheel
Rim
 Part design
Spring
Shock absorber (Damper)
Wheel drum
Whole part assembled
 Manufacturing

Spring

Shock absorber
 Spring
The method for manufacturing a coiled spring having
high fatigue strength to be used for a suspension
spring of a car using a rod of tensile strength 1910 to
2020 N/mm2 and diameter 8 to 17 mm.

Cold coiling step

Hot setting step

Shock absorber

Made of steel sheets, and then rolled into two tubes

and connected together, then a die inside stamps the
part no., date and the brand name, then a vault seals
the bottom of the tube, this is called the base
assembly.
Dimensions
Thank you