Additively Manufactured Wheel Suspension System with Integrated Conductions

Abstract

Increasing urbanisation and growing environmental awareness in society require new and innovative vehicle concepts. In the present work, the design freedoms of additive manufacturing (AM) are used to develop a front-axle wheel suspension for a novel modular vehicle concept. The development of the suspension components is based on a new method using industry-standard load cases for the strength design of the components. To design the chassis components, the available installation space is determined, and a suitable configuration of the chassis components is defined. Furthermore, numerical methods are used to identify the component geometries that are suitable for the force flow. The optimisation setup is selected in such a way that it is possible to integrate information, energy, and material-carrying conductions into the suspension arms. High-strength light metals are used to minimise the component masses. Apertures are provided through the components for the routing of electrical conductors. The transport of fluids is realised by conductions integrated into the wishbones. The final geometries of the suspension components are then validated by a finite element analysis (FEA) of the overall suspension model. The results of the applied method are lightweight suspension components with a high degree of functional integration. This improves the vehicle package and achieves higher front-wheel clearance, increasing the possible steering angles and thus improving manoeuvrability. The saving of unsprung mass can improve handling and has a positive effect on the vehicle’s energy consumption. Furthermore, the sectional conduction integration is followed by a simplified assembly of the front-axle suspension.

Keywords

• additively manufactured
• wheel suspension
• integrated conductions