Design Scope

• Design of various sub-systems of Suspension and Steering Linkage
• Engineering Change Management, Test Fixture Design
• Design Optimization and inertia relief analysis for control arms
• Concept design and tolerance analysis
• Specification management
• Value Engineering
• Competitive Benchmarking
• FMEA support
• IMDS & REACh support

Domains

• Steering gear, rack & pinion, linkage & suspension

• Simulation studies to identify life-limiting regions for various load scenarios such as torque to failure & road loads
• Thermal and dynamic studies, including frequency response analyses
• Detailed stress distribution studies on rack bending in scenarios such as curb push-off & 4-point bending
• Field failure studies of housings & their redesign to withstand road loads
• Collapse of steering column for driver’s safety (various test scenarios)
• Topology optimization studies on column assembly for target frequencies
• Stiffness studies of column assembly in all operable conditions
• Studies on estimation of cam lever efforts
• Optimization of retention clips and energy absorbing (EA) straps

Linkage & Suspension Systems

• Topology optimization of Linkage & Suspension elements (control arms, tie rods and tension struts) for various target loads
• Metal forming analysis for inner ball joints & stabilizing bars
• Estimation of pull-out forces of ball pins
• DoE studies for selection of optimum parameters for radial and axial stiffness
• Fatigue life estimations on ball studs for radial loads
• Assembly process and articulation of bellows and optimization of profiles