Design and analysis of automotive lightweight materials suspension based on finite element analysis

In this paper, an integrated method for the design of suspension components with lightweight materials is proposed. Starting from the well-established design flow for chassis components, the paper analyse the manufacturing and design aspect which are mutual dependent in composite structures, providing technical guidance. The proposed design methodology is applied to an innovative suspension archetype patented by Magneti Marelli, F.L.E.C.S. (Flexible Link Elevated Compliance Suspension). First, an analysis of available lightweight material is carried out to define which one best fits the design requirements in terms of density, stiffness, cost and manufacturability. Second, structural simulations, based on finite element analysis, are performed to investigate the influence of the thickness and material on the elasto-kinematic performance of the suspension. According to the stress distribution, an optimization of the shape and the stacking sequence of the component is performed. The results show that 8.5 mm carbon fibre reinforced epoxy is the best solution for the blades, and 5 mm aluminium alloy for the reinforcement tube wall thickness. Third, with respect to the final design, an adhesive interface is analysed and designed, using the Goland-Reissner model.