ABSTRACT:
This research paper gives a comprehensive insight into the
multibody dynamics of an All-Terrain Vehicle suspension system,
with a focus on the design and structural analysis of knuckle. The
dynamic analysis was conducted using Altair MotionView, where a
camber change of -2.8 to +2 degrees and a toe change of -4 to +3.3
degrees were observed during a bump and drop travel of 80mm.
Through iterative adjustments to the hardpoints, the geometry was
optimized to achieve a camber change in the range of -3 to +3
degrees and a toe change of less than 5 degrees, changes were done
progressively to the hardpoints. This optimisation was positive with
the purpose of increasing the agility and solidity of the ATV as a
vehicle. The knuckle was designed based on these optimized
hardpoints, incorporating the upper ball joint mount, lower ball joint
mount, outer tie rod mount, and brake caliper mount. The design
objectives included achieving a factor of safety (FOS) between 1.4
and 1.8, a minimum life duration of 10,000 hours, and a
displacement of less than 10mm under operational loads. Also, we
had concluded to use AL-7075 T6 for its high Strength- to – weight
ratio, higher corrosive and fatigue resistance as well as pretreated
material The analysis results revealed a factor of safety of 1.61, a
displacement of 0.13mm, and a life cycle of 13,466.6 hours. These
results show that the present design has high feasibility to fine
challenging requirement of ATV operation.
This paper discusses the simultaneous use of multibody dynamics
analysis and optimization to design a very effective suspension
system. The merits of this research compared to other similar studies
are: The research is done in a mixed perspective unlike some studies
that deal with either the dynamic behaviour of the suspension system
or the structural integrity of the suspension system, this research
includes both in its study of ATV suspension system.
KEYWORDS: Multibody dynamics, ATV, Structural analysis,
Camber change, Toe change, factor of safety (FOS), Life cycle.