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SUSPENSIN.
Autor: Azcoitia Revuelta, Juan.
Director: Jimnez Octavio, Jess.
Entidad Colaboradora: ICAI Universidad Pontificia Comillas.
MacPherson
Bajo
Baja
Tringulo Doble
Alto
Alta
Peso
Coste econmico
Rendimiento
mecnico
Medio
Medio
Medio
Alto
Alto
Alto
As mismo se identificaron las principales topologas en las que se pueden agrupar los
tringulos de suspensin, analizando sus caractersticas ms relevantes.
Topologas
Caractersticas
Peso
Espacio
ocupado
Resistencia
En forma de
L
Normal
Bajo
Tipo
Wishbone
Normal
Alto
En forma de A
Normal
Normal
Alta
Aplicacin a
turismos
Alta
Media
Baja
Alto
Medio
Topologa en forma de L
Material
Lmite elstico
Masa
Volumen
Aprueba el criterio de
aceptacin
Acero 1020
350 MPa
3,6 Kg
456560,47 mm^3
Topologa Wishbone
Material
Lmite elstico
Masa
Volumen
Aprueba el criterio de
aceptacin
Aluminio 1060
96 MPa
3,9 Kg
1467712,84mm^3
Topologa en forma de A
Material
Lmite elstico
Masa
Volumen
Aprueba el criterio de
aceptacin
PET
90 MPa
2,9 Kg
2095387,42mm^3
Diseo libre
Material
Lmite elstico
Masa
Aprueba el criterio de
aceptacin
Aluminio 2014
95 MPa
4,6 Kg
- Fase de fabricacin:
En esta fase se propuso un proceso de fabricacin para cada pieza, realizando un estudio
slido y riguroso de este, analizando los parmetros ms importantes en cada caso,
describiendo en el contexto de una cadena de produccin, la maquinaria y la mano de
obra necesaria para llevarlo a cabo.
A continuacin se ofrece un cuadro resumen por cada caso, que recoge la solucin
propuesta para cada una de las cuatro piezas diseadas.
Topologa en forma de L
Proceso de fabricacin
Material
N Mquinas que
intervienen
N de Operarios que
intervienen
Soldadura, Desbaste,
Corte Lser
Aluminio 1060
11
13
Topologa en forma de A
Proceso de fabricacin
Inyeccin de PET
Material
PET 35%
N Mquinas que
intervienen
N de Operarios que
intervienen
1
3
Proceso de fabricacin
Material
N Mquinas que
intervienen
N de Operarios que
intervienen
4 Conclusin
Del satisfactorio alcance de los objetivos establecidos se desprende el xito de un
trabajo serio, slido, y riguroso. En el que a travs de un completo y enriquecedor
estudio de la materia, de la proposicin de un planteamiento eficaz y riguroso con la
realidad, del inteligente uso de una variada mezcolanza de herramientas informticas, de
un arduo y crtico ejercicio de anlisis y comprensin, y del enorme esfuerzo
consagrado a la permanente bsqueda de la excelencia, se cubrieron los objetivos
inicialmente fijados satisfactoriamente, resultando en un completo y slido estudio del
diseo de un tren MacPherson y de su tringulo de suspensin, obteniendo cuatro
diseos optimizados de este ltimo.
PROJECT ABSTRACT
1. Introduction
Man has faced innumerable challenges throughout history, one of them with no doubt,
the transport of merchandise, goods, etc
Since the invention of the wheel, this target has been reached, and over some decades in
many different ways. The most popular and the one which has impacted more strongly
in the human being life, is the car, for which the suspension conception evolution has
resulted on a driving improvement,---------------One of the most important and popular suspension is the MacPherson, being one of the
first independent suspensions because is the cheapest, lightest and more functional tan
most of its competitors. Almost every rear-wheel drive mid-range and low-end vehicles
include this suspension type, as the Volkswagen Golf.
Just one suspension arm is needed by this kind of suspension, commonly named
suspension triangle.
This piece will be in charge of absorbing all longitudinal and transversal efforts that
could be submitted to the vehicle front train and so the own car.
Dimensioning and conception are really important facts, it is so, that the evolution
design of this piece has enabled to save costs to manufacturers and also paliate vehicles
ecollogical footprint, thus obataining good mechanical performance and lighter pieces.
In this context, arises the motivation to perform a study about this kind of front train so
usual in current vehicles, whereby the distribution of efforts in each piece will be
known. And using previous data, the performance of a more specific study about
dimensioning and conception of the suspension triangle.
In this phase, a careful study of the considered mechanical assembly was performed,
and three different topologies were identified in which the suspension triangles that are
actually on the market could be integrated, as well as the materials and fabrication
processes typically use don the conformation of this kind of piece.
-
In this phase, four pieces of suspension triangles were designed (free and original
design, in which three of them reproduce the identified topologies), optimizing its
dimensioning, following an acceptation criteria carefully established.
For this:
1. Objectives and methodology to follow were established on a reasonably and
effective way.
2. A calculus method of efforts of an standard MacPherson was proposed, aiming
the obtention of efforts that affect the suspension triangle on determined
situations.
3. A kinematic scheme equivalent to the considered mechanical assembly was
established. Implementing a model that allows the obtention of correct results.
4. The efforts to which the assembly would be affected in different situations were
considered.
5. An implantation form of these efforts was proposed, while maintaining the
isostatism hypothesis.
6. The distribution of efforts on the MacPherson train were calculated, identifying
the efforts on every single component of it. This distribution was subsequently
analyzed and validated.
7. Hypothesis were established and decisions taken, enabling the simulation of the
designed pieces on a simple and rigorous way similar to reality,
8. A rigorous and fundamental acceptation criteria of the pieces was identified.
9. The appropriate material was chosen for each case, discerning between different
possibilities.
10. Four pieces were designed, calculating the distribution of tensions and produced
displacements, analyzing and facing those results to the acceptation criteria and
obtaining four optimized designs.
- Manufacturing phase:
In this phase a detailed manufacturing study of each separated piece was performed,
from which, as a result, a solid description of how the manufacturing of each studied
cases should be performed, keeping in mind the wide range of existing possibilities,
materials, machines, needed operators, manufacturing times and costs.
Specifically, for each case:
1. The most adequate manufacturing process was identified, offering a rigorous
comparative analysis between the most advantageous a priori options,
identifying pros and contras of each case,
2. A detailed manufacturing process was proposed, in which every phase that
intervenes on it was identified and described, as operations to perform.
3. A calculus set necessary for the most relevant parameters was performed.
4. A solution for the hypothetical production chain was proposed, detailing the
machinery and necessary operators to carry out the process satisfactorily, as well
as the times and manufacturing costs when it has been necessary.
5. Calculus and simulations of the manufacturing process were realized when
necessary.
Finally, to conclude the work, an economic study was performed.
In this phase its been possible to understand the most important characteristics of the
MacPherson suspension, as well as its advantages and principal disadvantages regarding
to its most powerful competitor, the double triangle suspension.
Characteristics
MacPherson
Double Triangle
Occupied Space
Low
High
Complexity
Low
High
Weght
Medium
High
Economic Cost
Medium
High
Mechanical Yield
Medium
High
Likewise, the main topologies in which the suspension triangles could be grouped were
identified, analyzing its most relevant characteristics.
Characteristic
Topologies
Weight
En forma de L
En forma de A
Normal
Tipo
Wishbone
Normal
Occupied Space
Low
High
Medium
Resistance
Normal
Normal
High
Aplication to cars
High
Medium
Low
High
In this phase four pieces of suspension triangle were designed, following a free and
original way, and three reproducing the previous identified topologies.
Being proposed a efforts distribution calculus method, the four pieces were designed,
obtaining as result four optimized designs.
The efforts found, and afterwards used were:
FUERZAS OBTENIDAS
Frenada disco
Frenada a motor
Esfuerzo excepcional 1
Esfuerzo excepcional 2
And the proponed solutions were:
Topology L
Material
Elastic Limit
Mass
Volume
Acceptation criteria
passed
Steel 1020
350 MPa
3,6 Kg
456560,47 mm^3
Topology Wishbone
Material
Elastic Limit
Mass
Volume
Acceptation criteria
passed
Aluminum 1060
96 MPa
3,9 Kg
1467712,84mm^3
Topology A
Material
Elastic Limit
Mass
Volume
Acceptation criteria
passed
PET 35
95 MPa
2,9 Kg
2095387,42mm^3
Free design
Material
Aluminum 2014
Elastic Limit
Mass
Volume
Acceptation criteria
passed
96 MPa
4,6 Kg
- Fabrication phase:
In this phase a fabrication process was proponed for each piece, making a solid and
rigorous study of fabrication, identifying the most important parameters and calculating
them. As well as defining the machines and men needed to accomplish it.
The following tables, resume the solutions proponed in each case:
L Topology
Fabrication process
Material
N Machines
N Men
Heat stamp
Steel 1020
10
10
Wishbone Topology
Fabrication process
Material
Aluminum 1060
N Machines
11
N Men
13
A Topology
Fabrication process
PET Iyection
Material
PET 35%
N Machines
N Men
Fabrication process
Heat stamp
Material
Aluminum 2014
N Machines
N Men
12
4 Conclusions
The objectives established at the beginning were accomplish, thanks to a complete and
solid study of the subject, through an efficient method, faithful to reality, an intelligent
use of a variety of informatic tools, a critic analyses exercise, and a huge effort.