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WHITE PAPER

Vehicle Suspension Analysis

CONTENTS

Introduction 1

Role of vehicle
suspension 2

Motion analysis 2

Motion analysis using

COSMOSMotion 3

Real-life example 4-5

Exporting loads to
COSMOSWorks 6-7

Automating
analysis using
COSMOSMotion API 7

COSMOS
SolidWorks Corporation
 INTRODUCTION

COSMOSMotion is a simulation software package for motion study of any

mechanism. Motion study is a term for simulating and analyzing the
movement of mechanical assemblies and mechanisms. Motion studies are
two types; one is kinematics and the other dynamics. Kinematics is the study
of motion without regard to forces that cause it, and dynamics is the study of
motions that result from forces. Kinematic simulations show the physical
positions of all the parts in an assembly with respect to the time as it goes
through a cycle. Dynamic simulation shows joint reactions, inertial forces.

This paper mainly deals with the vehicle suspension analysis using
COSMOSMotion, and how an automotive designer can optimize their
suspension design using COSMOSMotion simulation software package.
COSMOSMotion is a perfect simulation tool to perform dynamic and
kinematic analysis of any mechanism. Mechanisms are represented as
assemblies of rigid components and each component has certain degrees
of freedom.
Design optimization can
This paper also addresses how a design engineer can use COSMOSMotion on
increase the value of a product
real time mechanisms like vehicle suspension, and how he can succeed in
by improving its performance
getting satisfactory results and also saving valuable time and money. The
within its operating
following Fig 1 is CSUN Formula SAE 2005-2006 race car front and back
environment.
suspension on which CSUN students performed dynamic analysis using
COSMOSMotion and COSMOSWorks and they competed with other schools in
West competition in Fontana in June 2006.

Figure 1
CSUN Formula SAE Race
Car Suspension

COSMOS V E H I C L E S U S P E N S I O N A N A LY S I S no. 1

If the design engineer can refine
his problem definition to a single
objective - or one objective at a
time - the optimization process
becomes easier.
COSMOS
R O L E O F V E H I C L E S U S P E N S I O N / M O T I O N A N A LY S I S M E S H I N G
Role of vehicle suspension
Suspension is the term given to the system of springs, shock absorbers and
linkages that connects a vehicle to its wheels. Suspension systems serve a
dual purpose - contributing to the vehicle's handling and braking for safety
and driving pleasure, and keeping vehicle occupants comfortable and
reasonably well isolated from road noise, bumps, and vibrations. Suspension
system is an assembly used to support weight, absorb and dampen road
shock, and help maintain tire contact as well as proper wheel to chassis
relationship. A vehicle in motion is more than wheels turning. As the wheel
revolves, the suspension system is in a dynamic state of balance,
continuously compensating and adjusting for changing driving conditions.
Several forces affect the tire to road contact of a vehicle. Vehicle dynamics is
the study of these forces and their effects on a vehicle in motion. Road
isolation is the vehicle's ability to absorb or isolate road shock from the
passenger; the degree to which this is accomplished is controlled by the
condition of the suspension system and its components. A properly
functioning suspension system allows the vehicle body to ride relatively
undisturbed while traveling over rough roads. Suspension design will affect
the handling of a vehicle.
Hence, it is very important to analyze vehicle suspension components before
manufacturing. Dynamic analysis has to be performed on a vehicle
suspension to analyze their components and also to see how they are going
to perform in worst-case scenario.
Motion analysis
The traditional method of performing dynamic and kinematic analysis of any
mechanism is preparing the data, solving the algorithms, which involves the
solution of simultaneous equations, and analyzing the results. For a complex
mechanism like vehicle suspension shown in the following Fig 2., solving the
dynamic equations for motion "by hand" requires intensive calculations, and
even with the help of computerized spreadsheet it may take a few hours to
get the results and plot the graphs. One can develop a program using
software to solve the dynamic equations of motion, but if the geometry of any
component changes then the whole program has to be changed again. A
design engineer can successfully overcome these problems in motion
analysis by using COSMOSMotion simulation software.
V E H I C L E S U S P E N S I O N A N A LY S I S no. 2
 M O T I O N A N A LY S I S U S I N G C O S M O S M O T I O N

Figure 2
CSUN FSAE Race Car
suspension model

Motion analysis using COSMOSMotion

COSMOSMotion is a simulation software package to analyze and optimize a
If the engineer selects too many
mechanism, and it is embedded in the SolidWorks interface. It enables
variables, or too few, the
engineers to model 3D mechanical systems as "virtual prototypes" and can
effectiveness of the analysis can
produce kinematic and dynamic results such as acceleration, joint reaction
be hampered.
forces, and inertial forces.

COSMOSMotion helps to reduce the number of physical prototypes needed in

product development. And also, an engineer will be able to increase the
efficiency of the product and can eliminate the expense caused by design
changes late in the manufacturing process. COSMOSMotion speeds up the
process by reducing costly design change iterations. It enables an engineer to
design and simulate moving assemblies so that you can find and correct
design mistakes before building the physical prototypes. It also calculates
the loads that can be used to define load cases for structural analysis.

Motion data, such as forces, accelerations, velocities, and the exact locations
of joints or points on geometry can be extracted using COSMOSMotion.
Forces that result from motion are of particular interest because they can be
used as loads for FEA of individual members in COSMOSWorks environment.
Typically, the highest load for a cycle is used to perform a linear static Finite
Element Analysis (FEA) of critical individual components of a mechanism.
Integration of SolidWorks (solid modeling), COSMOSMotion(motion
simulation), and COSMOSWorks (FEA) software can greatly streamline this
process - especially important when studying design alternatives, where
many analyses are required.

COSMOS V E H I C L E S U S P E N S I O N A N A LY S I S no. 3
- REAL-LIFE EXAMPLE
The two most frequently used
methods of shape optimization
are gradient search and design
of experiments (DoE).
COSMOS
Real- life example
CSUN FSAE 2005-2006 RACECAR
Every year CSUN students build their own style Formula racecars. The design
and fabrication of the FSAE racecar takes place over a period of nine months
and is used as a training ground for young and innovative engineers in
preparation for the engineering industry. This project employs the skills
required in an engineering firm, from the design process to the fabrication
process, where each step is always taking cost, ease of manufacturing, time,
and safety into consideration. Designing is done with the help of CAD tools
such as SolidWorks, COSMOS and other CAD tools. Modelling of the car
components is done using SolidWorks and component analysis is done using
COSMOS. CSUN FSAE 2005-2006 racecar suspension was analyzed and
optimized using COSMOSMotion.
A complete force analysis of CSUN Formula SAE 2006 racecar suspension was
performed with help of SolidWorks, COSMOSMotion, and COSMOSWorks.
Initially an Excel macro was created to analyze the road load conditions in
worst-case scenario, including (1) accelerating, (2) braking, (3) cornering with
bump and braking, and (4) cornering with bump and accelerating. Vehicle
suspension components were assembled using SolidWorks and their
appropriate joints were defined to create a mechanism using COSMOSMotion
simulation software. Then, the road loads were applied to the suspension
assembly in order to analyze the reaction forces between suspension
components such as A-arm brackets, uprights, pittman arm, shock mount,
and pushrods.
V E H I C L E S U S P E N S I O N A N A LY S I S no. 4
- REAL-LIFE EXAMPLE
Sensitivity studies can point the
engineer to the most significant
parameters as well as the range
of values having the most impact
on the objective.
COSMOS
To analyze the vehicle suspension using COSMOSMotion, an engineer needs
to know:
1. Each joint in the mechanism will have how many degrees of freedom
2. Spring stiffness and damping force in the shock absorber
3. Which parts are moving and which parts are fixed.
4. Input loads such as normal force, lateral force and longitudinal force.
Figure 4
Front suspension model
First step in suspension analysis using COSMOSMotion involves defining all
the components in the suspension assembly model as moving or grounded
parts accordingly. After which the joints and joint primitives are generated
automatically from SolidWorks assembly mates. For example, a spherical
joint can be generated automatically from SolidWroks assembly mate such as
point-to-point coincident joint.
Next step involves adding a spring, either torsional or translational according
to the design requirement, and defining the spring stiffness and also adding
damper in the Shock cylinder and defining the damping force. And finally,
applying the calculated road loads in worst - case scenario (1) cornering with
bump and braking, and (2) cornering with bump and accelerating.
Ability of COSMOSMotion to detect and fix interferences in the assembly
model without switching between software is one of the primary benefits of
integrating COSMOSMotion and SolidWorks. The motion of a particular joint
or surface of point on component can be plotted as a line. After running the
simulation one can plot all the results like reaction forces in three directions
on each joint as shown in the following Fig.
V E H I C L E S U S P E N S I O N A N A LY S I S no. 5

The engineer who undertakes
optimization will get the best
value out of the technology by
performing optimization in the
early stages of the design
process.
COSMOS
EXPORTING LOADS TO COSMOSWORKS
Figure 4
Rear suspension results
using COSMOSMotion
Exporting loads to COSMOSWorks
Forces that result from COSMOSMotion can be used as loads for structural
analysis of individual components. COSMOSMotion allows you to export
reaction force results in a form suitable for import by many Finite Element
Analysis (FEA) programs, where one can predict the component stresses,
deflections and Factor of Safetry check. COSMOSWorks is a FEA tool, which is
also embedded in SolidWorks. One can export COSMOSMotion reaction force
results of a vehicle suspension component to COSMOSWorks to perform FEA.
All COSMOSMotion entity property dialog boxes contain an FEA tab. On each
of these tabs, one can select faces or edges on the part where the entity is
attached. These faces and/or edges become the bearing surfaces for the
forces calculated by COSMOSMotion. When the force data is transferred to
the FEA application, the forces and moments are distributed onto the
selected faces and edges. One can choose to define the bearing surface at
the time you create an entity or at the time you export the results to the FEA
application. Once the bearing surface is defined, it is used for subsequent
transfers to the FEA application.
An engineer can perform FEA analysis on each vehicle suspension component
by exporting loads that result from COSMOSMotion. The following figure shows
upright component of racecar suspension on which FEA has been performed
using COSMOSWorks by exporting loads that result from COSMOSMotion, and
the component has been optimized by reducing its weight.
V E H I C L E S U S P E N S I O N A N A LY S I S no. 6
 EXPORTING LOADS TO COSMOSWORKS

The reaction forces on the upright component of suspension assembly after

running the simulation are shown in the figure below. When loads are
exported from COSMOSMotion to COSMOSWorks, the loads and their
directions will be defined automatically in COSMOSWorks as shown in the
figure. Mesh the component and run the design scenario. The FEA results
Engineers planning to use can be displayed as shown in the figure below.
optimization as a tool for
improving designs and products
need to clear their minds of any
pre-conceived ideas of what
constitutes "optimal."

Automating analysis using COSMOSMotion API

An Engineer can automate the vehicle suspension analysis using application
programming interface. SolidWorks supports application programming
interface as well as COSMOSMotion. A macro can be developed using
COSMOSMotion, which can automate the motion simulation. By running a
macro one can run the simulation, add joints, and all those things which you
can do manually in COSMOSMotion. And also you can connect
COSMOSMotion to the spreadsheet using API, where you can input all the
forces in spreadsheet and run the program all the results will be displayed
in spreadsheet.

COSMOS V E H I C L E S U S P E N S I O N A N A LY S I S no. 7
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