Last modified: 31 Jan 2006

Suspension wishbone

An automobile suspension component is experiencing fatigue cracking under repeated loading. The cracking was caused by high local stresses.

The design objective is to reshape the component, in order to reduce the maximum stress by at least 10%.

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Last modified: 31 Jan 2006

Steering knuckle

A steering knuckle has been designed for the prescribed parameters of front wheel geometry (camber, caster, toe-in and king-pin inclination). The design was based on the assumption of a rigid component.

The design objective is to reshape the steering knuckle so that the originally prescribed camber and toe-in angles are maintained as closely as possible under the extreme cornering loads.

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Last modified: 31 Jan 2006

Injection molded component

A plastic injection molded component prototype was designed based on 'engineering experience' with similar products.

The design objective is to reduce the component weight by 20%, without increasing the displacement of the loaded point under given loads.

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Last modified: 31 Jan 2006

Automotive HVAC door

An automobile HVAC door was found to be bending excessively under air pressure load incidents on it through the duct. The bending of the door compromised the seal so that airflow was not contained at the door but instead continued along through the duct.

The design objective is to reshape the component so that the opening around the edges of the door is reduced. This would improve the air seal.

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Last modified: 31 Jan 2006

Steering shaft component

A shaft in an automotive component was cracking in the same region consistently under experimentation.

A review of the component resulted in the redesign process presented, in which the stress concentration in the shaft is attempted to be reduced by at least 10%.

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Last modified: 31 Jan 2006

Suspension arm

An automobile suspension component experiences high local stresses.

The design objective is to modify the design of the component so that the maximum stress is reduced by at least 10%.

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Last modified: 31 Jan 2006

Wheel brace

Application of an extensive amount of torque on a standard wheel brace caused a considerable stress concentration at the connection point adjoining the two arms.

The design objective is to change the shape of the brace to reduce this stress build-up to an acceptable working level. Given that the wheel brace is made of steel and considerably heavy to begin with, it is also required that this task be achieved without a further increase in weight.

+ Download PDF 1.87 MB

Last modified: 31 Jan 2006

Rear cross-member

As part of an overall weight reduction program for an automotive suspension component system, the weight of the rear cross-member was to be reduced by as much as possible.

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Last modified: 31 Jan 2006

Differential housing

A differential blade was vibrating at a frequency that was in resonance with the gear teeth meshing frequency, creating some noise deemed to be irritating to the occupants of the vehicle.

The objective is to increase the first modal frequency, and hence reduce the audible noise of the component.

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Last modified: 31 Jan 2006

Axle

A high stress concentration is occurring in the axle, resulting in crack propagation and ultimate failure.

The objective of the iterative design improvement is to reduce the high stress by at least 10%.

+ Download PDF 362.17 kB