The Suspension System of the 2009 Cooper Union FSAE Vehicle: A Comprehensive Design Review

Dennis Robertson; George J. Delagrammatikas

doi:10.4271/2010-01-0311

This work details the process employed to design the 2009 Cooper Union FSAE® suspension system, spanning the overarching design philosophy, configuration selection, analysis, fabrication, and implementation, while offering recommendations to those especially new to the field. The design methodology illustrated here provides a systematic approach to suspension geometry, material selection, packaging, and construction. Though this paper serves as a starting point for FSAE® suspension designers, it provides a succinct overview for those interested in general suspension design fundamentals.

The design process began with the selection of a suspension configuration, geometries, and kinematics, which were driven in part by tire data, desired bulk vehicle dynamics characteristics, and overall geometric variability. The springs and adjustable dampers were then selected as the front and rear anti-roll bar properties were concurrently designed. The uprights were defined by reconciling a series of mutually conflicting constraints imposed by their overall geometry, the A-arm locations and kinematics, wheel hubs, bearing selection, tie rods (front), the drive axles (rear), toe adjustment rods (rear), manufacturability, and mechanical properties.

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The Suspension System of the 2009 Cooper Union FSAE Vehicle: A Comprehensive Design Review 2010-01-0311

SAE MOBILUS