Introduc on

Vehicle Dynamics is the study of mo on of a car and its behavior during the interac on with the
driver and environment. It generally consists of suspension system, steering system and wheels
and tyres.

Objec ves

● The main goal is to design a suspension system and steering system which will provide a
smooth driving experience.
● The project should be cost effec ve plus should not compromise on safety of the driver.
● To reduce unsprung mass.
● To implement an dive & an squat.
● To minimize compliances in the system.
● To design a steering system considering driver’s ergonomics.
● To achieve Ackermann Percentage above 90 %.
● To achieve Steering ra o between 3-5.
● To study tyre models.

Methodology

The design of Suspension and steering system should be such that it should sa sfy following
condi ons:-
● The design procedure must follow according to the rules and regula ons in the
rulebook.
● Roll center sufficiently above ground for good lateral stability.
● Small varia ons in camber and toe angles during the desired wheel travel.
● Usable wheel travel of at least 50 mm (25 mm jounce and 25mm rebound).
● Steering system free play should be under seven degrees (7°) total measured at the
steering wheel.
●
Design specifica ons

Our car has Double wishbone Pull Rod to Upper A-arm at the front wheels and Double
wishbone Pushrod to lower A-arm at the rear wheels.
(Photo of suspension system)
The Suspension parameters are
Parameters Front Rear

Jounce and Rebound (mm) 30 30

Mo on Ra o 0.6 0.59

Wheel Rate (N/mm) 18.914 15.240

Ride Rate (N/mm) 17.944 14.6044

Roll Rate (N.mm/deg) 206.084 148.657

Ride Frequency (Hz) 2.82 Hz 2.75 Hz

An Dive /An Squat 51.11 % 14.90 %

An Dive An Squat

KPI (deg) 7.84° 11.82°

Castor (deg) 2.66° 5.31°

Scrub Radius (mm) 13.62 11.02

Suspension Design Travel 61 61

(mm)
The Steering parameters are
Parameters Details

Ackermann Percentage 95.7 %

Steering Ra o 4.8 : 1 & 0.2mm per degree

Steer Loca on 120 mm behind front wheel center

Steering wheel diameter 220mm

Rack travel and rota on 70mm & 240°

Steering torque 3Nm

Tie rod length 311.38 mm

Inner angle 22.31

Outer angle 16.64

Turn radius 4.5m

The Wheels and Tyres parameters are

The wheels selected are 6 inch width, 22mm offset, Magnesium Alloy Rims OZ for both front
and rear.
The res selected are 20.5 X 7.0 x 13 A2500, R25B Hoosier for both rear and front.
Geometries

Suspension Geometry

Steering Geometry
Lotus Suspension Analysis

As the suspension geometries are plo ed on solidworks, the points of the components are
further plo ed on the lotus suspension including the tyre data. Thus the suspension system is
tested through the Castor Angle, Camber Angle, Kingpin Angle and Toe Angle graphs.
Calcula on
The max longitudinal accelera on Ax = 0.28 g
The max lateral accelera on Ay = 2 g
However, the maximum accelera on experienced by the vehicle is during cornering
accompanied by braking and given by:
√(0.28)2+(2)2 = 2.02g
Thus, maximum accelera on = 2.02g
Now, the weight of the car is 350 kgs.
Wf: Wr = 49.58:50.41
∴Wf = 173.53 kg = 1702.33 N
∴Wr = 176.44 kg = 1730.87 N.
Weight on single wheels in steady-state is:
Wf (single) = 86.77 kg = 851.16 N
Wr (single) = 88.22 kg = 865.44 N
The total longitudinal load transfer can be calculated as ΔWlongitudinal =
(W∗HCG∗Ax)/wheelbase
ΔWlongitudinal = (300*319.83*0.28)/1600
Δ𝐖𝐥𝐨𝐧𝐠𝐢𝐭𝐮𝐝𝐢𝐧𝐚𝐥 = 16.8 𝐤𝐠 = 164.72 𝐍
The total lateral load transfer can be calculated as
ΔWlateral = (W*HCG*Ay)/track width
ΔWlateral = (300*319.83*2.02)/1150
Δ𝐖lateral = 168.53 𝐤𝐠 =1653.34 𝐍

However, the max load transfer can occur during cornering and braking. This will be the
diagonal load transfer on the front outer wheel.
ΔWdiagonal = √ (ΔWlongitudinal2+ΔWlateral2)
ΔWdiagonal = √ (164.72)2+(1653.34)2
Δ𝐖𝐝𝐢𝐚𝐠𝐨𝐧𝐚𝐥 = 169.37 𝐤𝐠= 1661.53 𝐍
Thus, the maximum load on a single wheel is:
ΔWmax = Wf (single) + ΔWdiagonal
Δ𝐖𝐦𝐚𝐱 = 256.13 𝐤𝐠𝐬 =2512.6 𝐍
SPRING RATES
Sprung mass = 225.112 kg (approx.)
The factor for sta c to dynamic condi ons: 2.1
According to the mass distribu on of 49.58 : 50.41 (Rear: Front)
Mass per wheel (Front) = 86.77 kg
Angle of inclina on of the strut = 86 (from horizontal)
Point of a achment of strut = 195 mm from chassis end (from suspension geometry)
Reac on force ac ng from the ground on the wheel= (86.77kg * 9.81) N =851.16N
Considering the A-arm hinges (A) as the point about which moment is taken;
The horizontal distance of reac on force from hinge point =255.30 mm from suspension
geometry
The horizontal distance of strut a achment point from hinge point =195 mm
By taking moment about hinge points:
851.16 * 225.112 = Spring Force * sin 86 * 195
Spring Force = 985 N
Considering the dynamic factor,
Dynamic force ac ng on the spring =2068.5 N
Hence,
Spring S ffness = Dynamic Spring Force / Deflec on
= 2068.5/ 60
=34.47 N/mm
By using a similar procedure,
For Rear
Spring Force =950.69 N
Dynamic Force ac ng on spring =1996.45 N
Spring S ffness = 33.27 N/mm

Components Design (CAD models)

Hub

A forged or cast piece of metal that an automobile wheel mounts to.

 Front Hub Rear Hub

Load Ac ng 3000 N 3000 N

Torque 350 N/m 350 N/m

Yield Strength

Deforma on

Factor of Safety

Upright

The upright a aches the wheel, brake rotor, hub, brake caliper and steering arm to the vehicle.
Upright analysis

Front Upright Rear Upright

Load Ac ng 3400 N 4000 N

Yield Strength 2.452*108

Deforma on

Factor of Safety 3.2 2.1

Rocker Arm

Rocker arm is used to connect the dampers to the A-arms.

Rocker arm analysis

 Front Rocker arm Rear Rocker arm

Load Ac ng 1738 N 2307 N

Yield Strength 2.75 * 108 2.75 * 108

Deforma on 5.467*10-2 1.133*10-1

Factor of Safety 4.2 2.2

A-arm

A-arm is a hinged suspension link between the chassis and the suspension upright or hub that
carries the wheel.
S

Front Rear Front Rear

Lower Lower Lower Lower

Load Ac ng

Yield Strength 231.94 231.94 231.94 231.94

Deforma on 0.126mm 0.0088mm 0.0166mm 0.189mm

Factor of Safety 13.3 11.2 13.08 10.78

Damper

The damper's func on is to restrain undesirable bounce of the sprung vehicle mass and to
restrain the wheel assembly from losing ground contact by being excited at its natural
frequency. We selected DNM RCP-2S as it was mee ng our specifica on according to our
calcula ons.
 Weight 0.41 KG ( 0.91 Ib ), 210 mm ( 8.27 inch )

Adjustments Rebound / Compression / Preload / Air Pressure

Adjustable/Big impact

Damper sha Hard chromed shock Ø 12 mm ( 0.47 inch ) sha .

Dark hard-anodized AL-7075 shock body.

Riding style AM / FR / DH

Color Black

Available Size Eye to Eye x 190 × 51 mm ( 7.48 × 2.01 inch)

Travel 200 × 56 mm ( 7.87 × 2.20 inch)
210 × 61 mm ( 8.27 × 2.40 inch)
220 × 66 mm ( 8.66 × 2.60 inch)
240 × 76 mm ( 9.45 × 2.99 inch)
265 × 85mm ( 10.43 ×3.34 inch)

Wheel
A wheel is a circular component that is intended to rotate on an axle bearing. We selected OZ
Racing Aluminum 4H 7J R13 for our car.

Steering Wheel

Rack and Pinion

The Rack & Pinion converts the rota on of the steering wheel into a swiveling movement of the
road wheels.

Components Assemblies

Steering Assembly
Suspension Assembly