Vehicle Suspension & Steering Components
Project Overview
Designed and optimized critical suspension and steering components for commercial vehicles, focusing on durability, manufacturability, and cost-effectiveness. The project involved complete lifecycle development from concept to production for a major automotive manufacturer.
Key Components Designed
- Front suspension knuckles: High-strength aluminum alloy components with integrated mounting points
- Steering linkages: Optimized for reduced play and improved response
- Control arms: Lightweight stamped steel design with reinforced bushing areas
- Bearing housings: Precision machined components for wheel hub assemblies
Design & Development Process
Requirements Analysis
Collaborated with automotive engineers to define performance specifications, load cases, and regulatory requirements including FMVSS standards. Conducted competitive benchmarking of existing solutions.
Concept Development
Created multiple design concepts using parametric modeling in SolidWorks. Evaluated alternatives based on stress distribution, weight, and manufacturing feasibility.
FEA Validation
Performed finite element analysis for static and dynamic loading conditions. Iteratively refined designs to achieve optimal stress distribution while minimizing weight.
Prototyping & Testing
Oversaw production of functional prototypes. Conducted lab and field testing including fatigue analysis, corrosion testing, and real-world durability trials.
Production Implementation
Developed detailed manufacturing drawings with GD&T per ASME Y14.5. Created assembly procedures and quality control documentation for high-volume production.
Technical Specifications
Materials
- Knuckles: A356-T6 aluminum alloy
- Control arms: SAE 1010 steel with zinc plating
- Bushings: Polyurethane composite
- Fasteners: Grade 8.8 corrosion-resistant steel
Performance
- Load capacity: 2,200 kg static / 3,500 kg dynamic
- Fatigue life: >500,000 cycles at design load
- Corrosion resistance: 1,000+ hours salt spray
- Operating temperature: -40°C to +120°C
Manufacturing
- Tolerance: ±0.1mm critical features
- Surface finish: Ra 1.6-3.2μm bearing surfaces
- Production rate: 250 units/hour
- Processes: Casting, CNC machining, stamping
Design Innovations
Weight Reduction
Implemented topology optimization techniques to reduce component weight by 18% while maintaining structural integrity through strategic rib placement and material distribution.
Modular Design
Developed interchangeable mounting interfaces allowing single component to serve multiple vehicle platforms, reducing SKUs by 40%.
Manufacturing Optimization
Redesigned components for reduced machining operations, implementing net-shape casting features that decreased production time by 22%.
Project Outcomes
Performance Improvements
- 20% reduction in unsprung mass improving ride quality and handling
- 15% increase in component lifespan through optimized stress distribution
- Reduced assembly time by 30% with self-locating features
Production Benefits
- 20% reduction in production time through design simplification
- 15% decrease in material defects via tolerance optimization
- 98% on-time delivery rate through cross-functional coordination
Quality Achievements
- Zero field failures in first production year
- 30% reduction in warranty claims compared to previous design
- Achieved ISO/TS 16949 quality standards