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.
