© April 2017 | IJIRT | Volume 3 Issue 11 | ISSN: 2349-6002

DESIGN AND ANALYSIS OF SUSPENSION SYSTEM

OF AN OFF ROAD VEHICLE (ALL TERRAIN
VEHICLE)

Manishkumar Manjhi1, Shaktiprasanna Khadanga2, Bibhutibhusan Sahoo3, SusarthakRath4,

Karankumar Guru 5 and P. Murarji6
1,3,4,5,6
Student, Mechanical Engineering Department, Gandhi Institute Of Engineering And Technology,
Gunupur, Odisha, India
2
Asst. Professor , Mechanical Engineering Department, Gandhi Institute Of Engineering And
Technology, Gunupur, Odisha, India

Abstract—An ATV is the vehicle which is designed to
move through all terrains. We are using this vehicle for
various range of purposes such as military purpose,
rescue purpose during natural calamities and also for
forest inspections. [1] Suspension system of this vehicle
should be strong enough so that it will give better ride
quality and maximum comfort to the driver. Double
wishbone suspension system is selected and is designed in
LSA (Lotus Suspension Analysis).After designing the
hard points are received and using them A-arms are
designed by using SOLIDWORKS and CATIA software
and after that we selected the material to fabricate it but
before fabrication we have analysed the various stresses
acting upon it by ANSYS. We have also designed front
and rear uprights and analysed it by using ANSYS. This
project aims at selecting, analysing and fabricating a
suspension system of ATV which will capable of handling
at rough terrains.
Index Terms—Camber,Castor,Double Wishbone
Suspension System, Roll Centre Height,Toe,Track
width,Upright,Wheelbase.
I. INTRODUCTION
Suspension system is one of the major component of
the vehicle which is used to have a maximum traction
effort in between road and tyres and to provide
maximum possible comfort to the driver. The contact
between the road and tyres are maintained due to the
load applied by the vehicle which acts through the
tyres and suspension system. We have to design by
keeping 2 aspects in our mind:
1. Uneven surface of roads.
2. Variations in the load.
Road irregularities includes the big hills and small
uneven surfaces which may be termed as high
frequency (hills) and low frequency (uneven
surfaces).Variations in loads are due to various aspects
like load during cornering, load during braking, load
during acceleration [2]. So to sustain in these cases we
must have reliable suspension system which should be
soft for giving comfort to the driver and hard for
carrying uneven loads while travelling in the hills and
mountains.
Suspension system reduces [3] reaction force generated
due to obstructions on the path of the vehicle. This
reaction force’s magnitude is directly proportional to
the unsprung mass of the vehicle. With higher sprung
to unsprung weight ratio we can achieve more
reduction of reaction force effecting both vehicle and
the occupants and can also enhance vehicle control
ability.So suspension system is mainly divided into 2
categories:Dependent Suspension System: Here in this
suspension system the movement of one wheel
depends upon another wheel.Independent Suspension
System:Here in this suspension system the movement
of one wheel does not depends upon another wheel.
Here each wheel is independent of each other.
So we have decided to choose Double Wishbone
System as per our use of the vehicle. Double wishbone
suspension system consist of two a-arms (upper
wishbone and lower wishbone) usually of different
length along with a spring and a damper.This type of
suspension system provides negative camber at the
time of ride and it has[4] an excessive load bearing
capacity. It also provides better stability and roll
height.

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II. DESIGN METHODOLGY  have better traction during cornering.
Before designing the suspension system of vehicle we
have concentrate upon some of the basic parameters of
the vehicle required for it.So the basic parameters are:
1. Wheelbase:60 inch.
2. Track Width:Front-54 inch,
Rear-50 inch
3. Tire Radius:12 inch
4. Tire Width:8 inch
5. Sprung Mass:180 kg
6. Unsprung Mass:80 kg Fig1: Roll Axis is inclined toward the front.
So by using these parameters we started the process of
designing the[5] suspension system of the vehicle. We
have selected the LSA (Lotus Suspension Analysis)
software to design it.

2.1 LOTUS Suspension Analysis:

LOTUS suspension analysis tool is used for initial
outline of the vehicle. 3D models can be created and
modified in LOTUS Suspension Analysis (LSA).
Using LSA Hard points are drawn and graphical and
numerical [6]values can be found out. This modelling
approach allows user to make their own suspension Fig2: Roll Centre below CG.
models. The changes in camber angle, toe angle can be
displayed graphically against motions like roll motion,
We have taken Damper to lower wishbone for the front
bump motion, steering motion. Several parameters are
suspension and damper to upper wishbone in rear
considered to get the hard points of the suspension
suspension system.We have design by using[7] these
system like damping ratio, sprung and un-sprung
parameters and also by checking various properties
weight, spring rate, camber angle, caster angle, roll
such asroll motion, bump motion, steering motion.
centre, wheelbase, track width, toe angle, ground
These properties are controlled by controlling the
clearance.
camber,caster, toe ,kingpin angle etc.So after
So before designing in LSA we have design
designing we get the results as:
considerations:
Numerical value:
 Kingpin and caster angle are kept in such a way
Table1: Numerical results
that they can compensate each others camber gain, by
providing there individual function. Camber angle( Kerb Weight 0 deg 1.73deg
 A positive king pin angle is kept to help in &Suspension Travel)
steering the vehicle.
 Roll centre below CG to avoid jacking force. Caster angle 0.13 deg
 Front ride frequency is greater than rear. King pin angle 0.78deg
 Roll axis inclined towards front to give
understeer characteristic. Scrub radius (mm) 40.477
 Front double wishbone unequal parallel arm to
Toe In & Toe Out 0deg 0deg

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Graphical Representation:

Fig6:Graph between
Spring Travel Vs Wheel Travel
Fig3:Graph between
Castor Vs Travel After designing in the LSA we hardpoints of the
suspension system. [8]We will use these hardpoints as
the coordinates for designing the wishbones.
So, for designing the Front Wishbones the coordinates
are:

Fig4:Graph betweenToe
Angle Vs Travel

Fig7: Front Suspension Coordinates

And for designing the the Rear Wishbones the

coordinates are:

Fig5:Graph between
Camber Vs Travel

Fig8: Rear Suspension Coordinates

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 © April 2017 | IJIRT | Volume 3 Issue 11 | ISSN: 2349-6002
2.2design Of Wishbones:
Design of the suspension was carried out in Computer
Aided Designing (CAD) using CATIA deigning
softwareV5R21 and SOLIDWORKS for designing
purpose.
Design of wishbones[9] is the major step to construct a
suspension system. Initially, for designing we have
coordinates from LSA.
2.2.1Front Wishbones:
Double wishbone suspension system of unequal length
and parallel was implemented for Front suspension.
We finalize the shape of wishbone to be A/V as it can
distribute stresses over the members effectively.
Upper wishbone is shorter than lower wishbone. The
advantage of having different lengths is that when the
vehicle takes a turn a negative camber is induced
which increases the stability.[10] Often this
arrangement is titled as SLA (Short Long Arm). As we
are having damper to lower wishbone in front side so
the lower wishbone will be of A shape and the front
upper wishbone will of V shape. As we have caster
angle 0.13 deg which makes our front suspension
unequal and parallel. We will mount the spring in the
lower wishbone which will be tilted towards the rear
side.
Fig9:Front Lower A-Arm
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Fig10:Front Upper Arm
2.2.2Rear Suspension system:
It consists of equal A-arms and parallel arm design.
Independent equal A-arms are widely accepted as
camber changes can be easily eliminated. One end is
attached to the chassis and other end is attached to the
knuckle. A-arm provides large amount of travel and
mostly equal the front suspension system. At rear side
the camber angle and caster and also the toe angle will
the zero. For making toe angle zero we are connecting
a zero toe rod.
As we are having damper to upper wishbone in rear
side so the upper wishbone will be of A shape and the
rear lower wishbone will of V shape.As we have
caster and[11] camber angle 0deg which makes our
front suspension equal and parallel. We will mount
the spring in the upper wishbone which will be tilted
towards the front side.
Fig11: Rear Upper A-Arm
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Fig12: Rear Lower Arm
So in this way we had designed both the
wishbones.After designing of the wishbones we had
done the material selection by looking into various
parameters such as ultimate strength, yield strength
etc. The material selection was also based upon the
material strength to bear the loads acting in the
dynamic [12]condition. So the material considered
according to the market availability was AISI-4130 as
it was lighter in weight along with optimum cost.
Material selected-AISI 4130
Outer diameter-25.4mm
Inner diameter-19.8mm
Physical Properties Of Aisi 4130
Ultimate strength:560MPa
Carbon content: 0.28
Yield strength:460MPa
Elongation at break (in 50mm): 21.50%
Modulus of elasticity: 210GPa
Poisson’s ratio:0.3
Bulk modulus:140GPa
Density: 7.85 gm/cm3
2.3 Upright Design:
Upright is design by CATIA and SOLIDWORKS
software by using the proper tire dimensions. It is
designed in such a way that it could hold the upper and
lower pivot points of the a-arms and the output axle
long with the hub and brake callipers without any[13]
difficulties .After the designing it is validated using the
CATIA FEA package. After this it is tested by
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assembling all the remaining parts of the suspension
system.
Fig13:Front Upright Fig14: Rear Upright
III. ANALYSIS
After designing is over in CATIA [14]it is imported to
ANSYS simulation software (Computer Aided
Engineering). Analysis of suspension is done by using
ANSYS software. Several types of thermal analysis,
structural analysis can be made possible using ANSYS
software. Here we are conducting structural analysis
to define the boundary conditions and to determine the
stresses and deflection developed by applying various
loads.
For analyzing the whole system some basic
calculations are used [15]to calculate the values of
various loads acting on it. A certain amount of force
will be given in order to see the various deformations
which are going to be held during simulation. So to
check this we are using the FEA software ANSYS to
view these deformations.
3.1Analysis of wishbone:
For analysis of the wishbones a 3G newton amount of
force is given to check the strength of the design of the
wishbones. By this we calculated [16]the maximum
possible deformation and maximum stress developed
in the arms in the impact load conditions.
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Fig15: Stress Analysis of A-arms
3.2Upright Analysis:
The front and rear upright are analysed by FEA
analysis software ANSYS. The upright will give
support to the bearings of the hub which ultimately
allows[17] the wheels to rotate.The FEA analysis is
done by applying 2000N which gives some amount of
red zones on the upright.
So to harden the upright we fabricated it by using
aluminium alloy to give strength of that it can sustain
the forces acting on it. The front upright is of material
Aluminium alloy 7560 and rear upright is fabricated
by using Aluminium alloy 6061-T6.[18]Both the
uprights are having different material because of their
different design.
Fig16: Front Knuckle Fig 17: Rear Knuckle
IV. RESULTS
After Manufacturing the ATV various tests are.Those
tests includes both static and dynamic tests. The
following results are received from static conditions:
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1. Centre of Gravity Height: 18 inch
2. Ground Clearance:13 inch
3. Roll Centre Height
1. Front:230mm
2. Rear:260 mm
Dynamic results are received by testing the vehicle in
various terrains like mud, hills etc. We can further
modify the suspension system of the vehicle by using
trailing[19] and semi-trailing arm at rear side in the
spring will be mounted on knuckle and firewall.
Trailing arm and Semi- Trailing arms will be mounted
on the knuckle and the base of the chassis.
V. CONCLUSION
The paper describes about designing and analysing
suspension of an All Terrain Vehicle (ATV) and their
integration in the whole vehicle. The ATV has been
designed and analysed based on the facts of vehicle
dynamics. The primary objective of this paper was to
identify the design parameters of a vehicle with a
proper study of vehicle dynamics. This paper also
helps us to study and analyse the procedure of vehicle
suspension designing and to identify the performance
affecting parameters. It also helps to understand and
overcome the theoretical difficulties of vehicle
design.
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