Using Optimum Kinematics, I designed the full kinematic model for a suspension system. Targeting linear and predictable behavior. This involved tuning the geometry to gain toe gain under 0.2°, linear ARB and Rocker ratios, roll axis inclination under 0.1°, pitching under 1° during both maximum acceleration and braking. Less than 1/4" of jacking effects.
I went through over a hundred or more simulations manually to achieve kinematic targets.
External Design Review (Look at the Graphs!)
The suspension bellcranks were designed in OnShape, following the kinematic geometry from the kinematic model. Each iteration was validated through FEA in Fusion 360, achieving a safety factor is 2.25 while reducing weigh by 40% from un-skeletonized part. CNC toolpaths were generated in Fusion 360 CAM and machined in house on a Mach3Mill controlled router.
FEA Results
Designed back up uprights that can be welded out of 4130 Chromoly steel, that are 15% lighter than the billet aluminum uprights that do not need access to a 5 axis CNC or complex 3 axis CNC jobs at a safety factor of ~4. Bend calculations were taken into account.
A 2-week CAD project to explore fast design cycles for a Formula SAE EV car. Designed the entire vehicle tying to a single workspace, where all subsystems (chassis, suspension, powertrain). This workflow allows me to modify pickup points, packaging or any major geometry instantly and minimize the energy that goes into remodeling affected components.