Design of a Double Wishbone Baja SAE Suspension System

The Baja SAE Completion is an extreme off roading event that requires an effective suspension design to survive the many obstacles that make up the racecourses. Without an effective suspension the many participating teams will experience poor performance or even failure within their suspension. This research focuses on the development and optimization of a double wishbone suspension in both the front and rear. Additionally, the design and optimization of a sway bar attached to the rear suspension will be gone through. Both the front and rear suspension will be optimized through three simulations heave, roll, and steering through the use of Optimum Kinematics. The process for placing the coilovers to ensure they will move perpendicular to control arms throughout their travel and ensuring the coilovers length in fully compression and extension are not exceeded will be developed through the use of SolidWorks and Optimum Kinematics. An effective mounting location for the axles checking that the max plunge of 1 in. and bend angle of 45° is not exceeded will also be developed through the use of SolidWorks. A detailed description for determining the ride and roll characteristics of the suspension will also be worked through to determine the desired numerical characteristics for a rear sway bar. In addition, the process for determining a wall thickness of 0.12 in. and an outer diameter of 0.75 in. for the sway bar will be discussed. Followed by the discussions that need to be made to the roll bar The roll bar also features the ability to change to three different roll gradients through simple adjustments in the linkage system.