Mass Optimization of Automotive Radial Arm Using FEA for Modal and Static structural Analysis

Abstract

Abstract The radial arm is an important part of an automobile suspension system. A vehicle suspension system having radial arms that are connected to axle brackets through vertically arranged bushings. The radial arms are fabricated using sheet metal members that are assembled in a clam-shell arrangement. An important consideration in the design of radial arm is the natural frequencies and mode shapes for dynamic loading conditions along with stiffness. The present work is focused on mass optimization of radial arm for modal and static structural analysis. The work includes investigation of natural frequencies and mode shapes of the optimized design of radial arm and comparing with the static structural analysis results using Finite element analysis tool. The radial arm was modeled in Catia V5, finite element modeling was done in Altair Hypermesh and analysis was done using Optistruct solver. From the static stiffness analysis, it was observed that the mass of the assembly can be reduced for given loading and boundary conditions by carrying out design modifications to the assembly without changing the manufacturing process. It was found that mass has been reduced to 13% of baseline model and stiffness also increased in all the directions. Modal analysis results indicate that all the natural frequencies are well within the range of baseline model.