EMS5CAE: Computer Aided Engineering - Manufacturing Engineering Assessment Answer

Engineering Assessment Task

Objectives

The aim of this project is to conduct a finite element based structural, modal and harmonic response analysis of an RC double wishbone suspension system. The system and each component in the assembly must be scoped and investigated for the given boundary conditions and spring stiffness.

Then, you are to assign appropriate materials to the given model. The initial study must use structural steel for each component. Then, apply a different material for the rim and for the wishbones (such as ABS, PLA, Nylon, aluminium alloy etc.). Each wishbone arm must have the same material. Adjust the geometry as per your individual value at this location. Then modify these geometries to align with the first cut. For the modal, harmonic response and structural analysis, you are to consider –

? The vibrational frequency of members at different mode shapes with application of Standard Earth Gravity. (No Frequency is Zero Hz)

? Assigning appropriate materials for the rim and wishbone arms.

? What and where are the maximum stresses due to the given loading conditions.

? Where are the maximum stresses and is the solution independent of the mesh (conduct a mesh study).

? The range of operating frequencies that the structure will experience is up to ~50Hz. Is it likely there will be a problematic frequency for this force input within the given range of frequencies?

? Conduct a harmonic analysis to understand the change in stresses and deformations at the given problematic frequency.

? The boundary conditions (loads and supports) that are modelled must provide accurate representation for the following loading cases;

1. Force defined by components on the outer mid surface of the rim.

2. Moment on the 2 outer surfaces of the rim.

3. Remote displacement simulating a fixed location where a steering arm would be connected.

4. Spring fastened to the lower wishbone arm with the opposite end fastened at a given offset location.

5. Representation of the spherical and pin-type joints connecting the suspension assembly to the rim and vehicle. During post processing you must analyse the stress and deformation contours of the suspension, comment on the stress development within the assembly. Based on the results of initial analysis modify the material of both wishbones and evaluate the effect on the stress and deformation.

Are you able to change material and reduce the overall weight of the system while all the supports and boundary conditions remain the same? Having done the analysis and looked at the effect of the different materials and mesh, write a technical report of the design process.

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