Suspension

Outline
Introduction Suspension components Suspension type examples
Solid axle Double Wishbone MacPherson Strut

Introduce basic geometry

Suspension Purpose
Isolate passengers and cargo from vibration and shock

Improve mobility
Improve vehicle control

Basic Terminology
Sprung Mass
Mass of all components that do not move much when suspension is displaced. (given the frame as a fixed reference) (Frame, engine, passengers, etc,) Some suspension components are actually partially sprung mass

Basic Terminology
Unsprung Mass
Mass of components that move when suspension is displaced Minimizing the unsprung mass allows for more optimal suspension operation

Basic Terminology
Bump
Vertical displacement of entire sprung mass

Basic Terminology
Roll
Front View angular rotation of the sprung vehicle mass

Basic Terminology
Pitch
Side View angular rotation of the sprung vehicle mass

Basic Terminology
Roll Center
Center at which the sprung mass pivots about during a roll situation (lateral acceleration) This is a dynamic point: moves around throughout suspension travel

Basic Terminology
Pitch Center
Center at which the sprung mass pivots about during a Pitch situation (fore/aft acceleration) This is a dynamic point: moves around throughout suspension travel

Basic Terminology
Camber

Front View tilt of the tire.

Leaning the top of the tire inboard adds negative camber

Basic Terminology
Toe

Top view angle of the tire in a static situation

Turning the front of the tire in is referred to as adding toe in Important for both front and rear tires

Basic Terminology
Steering Axis

Axis about which the wheel/Tire rotate about during steering inputs
Also known as King Pin Axis

Basic Terminology
Caster Angle

Side view tilt of the steering axis.

Creates camber change with steering input Creates a restoring force for centering steering wheel

Basic Terminology
Caster Trail

Side view distance from the steering axis ground plain intersection and the contact patch center point
Creates a restoring force for centering steering wheel

Basic Terminology
Scrub Radius

Distance From which the ground plain intersection of the Steering axis and the center of the tire contact patch
Large effect on drivers feel and steering effort

Basic Terminology
Steering Arm

Line between the steering axis and there steering linkage tie rod

Basic Terminology
Bump Travel Vertical distance wheel is able to move up from static position, with reference to vehicles sprung mass Droop Travel Vertical distance wheel is able to move down from static position with reference to vehicles sprung mass

Passenger Comfort
The perception of vehicle comfort is very subjective. Much depends on the cabin conditions. The main objective of the designer is to minimize the rate of change of acceleration (jerk).

Trophy truck video

Front Independent double wishbone Suspension Rear Solid axle High horse power vehicle

Baja Buggy
Front Independent double wishbone Suspension Rear Independent double wishbone Suspension

Light weigh low horsepower vehicle

Extreme mobility

Control in extreme maneuvers

Simplified Quarter Car Model

Two Degree-ofFreedom System
However the longitudinal and lateral stiffness of most suspension cannot be totally disregarded

Simplified Half Car Model

Two Degree-of-Freedom System
However the longitudinal and lateral stiffness of most suspension cannot be totally disregarded

Components of Suspension
Tire Linkage Bearings, Bushings Springs Dampers Sprung / Unsprung Mass

Tire
Acts as both a spring and a damper These rates are affected by air pressure and tire construction.

Pivot Joints
Spherical & Roller bearings
High performance applications Minimal Compliance High Precision Low Stiction/Friction

Bushings
Low Cost Offers compliance

Spring Types
Leaf Springs
Used in many early applications Internal friction provides damping Provide Fore/Aft/Lateral location for the axle Heavy Prone to weaken over time

Spring Types
Torsion Bars
Little to no internal damping Low cost Often difficult to package

Spring Types
Coil Springs
Little to no internal damping Low cost Compact Size Used in many Suspension types

Solid Axle Suspensions

Applications: -Pick Up Trucks (Rear) -Stock Cars (Rear) -Rock Crawlers (Front & Rear)

Advantages
Fewer Individual Components Easier to cheaply manufacture and assemble Simplified drivetrain layout High Load Capacity Axle Components are protected Can use leaf or coil springs
Also can accept many different types of linkages to gain desired geometry

Solid wheel attachment

Minimal alignment eminence

Disadvantages
Disadvantages:
Higher Unsprung Weight
Can lead to wheel hop

Axle wrap when in a leaf spring configuration High Roll Center Height Not an Independent Design
Corners are coupled

Fixed Camber Angles

Camber Change
The diagram below shows how the camber is statically fixed, and does not change in rebound The middle diagram shows how the camber of the two wheels are linked to one another

Solid axle adjustability

As far as the static characteristics of the suspension the camber and castor are preset in the manufacturing of the axle housing
However the dynamic characteristics of the suspension are highly adjustable with various forms or bar linkages There are many different linkage designs for a solid axle ranging from leaf springs to multi-link suspension systems

Truck, NASCAR applications

Double Wishbone Suspension

With Unequal Length Upper and Lower Arms

Found On: -Stock Cars (Front)

-Corvettes (C5 &C6) (Front and Rear)

-Honda Civics (88-00) (Front) -Most Modern Sports Cars

Advantages
Arguably the best handling suspension design Wheel gains negative camber in bump Low Unsprung Weight Packaging does not compromise styling Low Height Many different geometry characteristics possible Designer can design suspension with minimal compromises Infinite adjustability, with the most ease Vehicles roll centers can be placed almost anywhere

Disadvantages
More expensive More components to make and assemble Alignment and fitment are critical to vehicle performance, large area of adjustment Tolerance of parts must be smaller Requires constant alignment checks for optimum performance More complex Design often becomes more complex because all suspension parameters are variable Frame has to be able to pick up a-arm inboard points Tire scrub occurs with vertical wheel displacement However this can be minimized during design

Double Wishbone Tuning

The double wishbones complexity enables it to be adjusted quite readily The suspension geometry can be adjusted in two distinct ways
Move the location of the inner Chassis attachment points Adjust the inclination of the upright and the pick-up locations on the upright

The camber, castor, roll center, etc. can all be individually adjusted on this type of suspension relatively easily.

Formula 1 Application

Suspension Types: MacPherson Strut

Invented by Earl S. MacPherson First used on the 1951 Ford Consul Ford held the patent for the Macpherson strut system by many rival companies invented similar systems to avoid Ford royalties

Suspension Types: MacPherson Strut

Advantages
Low production costs
Stamped construction

Preassembled
Strut body carries spring assembly

Compact
Simple mounting and no need for an upper control arm

Simplicity
Reduction in fasteners and alignment of vehicle suspension components.

Suspension Types: McPherson Strut

Disadvantages
Large camber variation
Body roll and wheel movement contribute to camber attitude

Vertically tall mounting position

This compromises vehicle styling

Rough ride
Some ride comfort may be lost, as it is hard to move smoothly because of bending input force

Dangerous replacement
The spring must be compressed and assembled on the strut body, this causes the handling of a charged spring.

Associated forces in the strut

Since the strut serves as the upper control arm as well as the damper it is required to provide the force to hold the wheel at the desired camber attitude.

Adjustment of MacPherson Strut

Since the strut governs the King pin axis as well as the camber of the tire, these two parameters are linked The adjustability of the MacPherson strut is limited, due to its simplicity Most adjustability of the suspension is achieved by modifying the location of the upper strut mounting location.

Suspension Types: MacPherson Strut

MacPherson Struts are widely used on a variety of cars today from the everyday road car to world class race cars