Final Project A (Family Name A-D): Stress Analysis of a Car Suspension in FEMAP
(Due on Sun, May 19)
Name: Massimiliano Repupilli
Project Statement A (Family Name A-D)
Consider the CAD model of a buggy car suspension system shown in Figure 1. We would like to model all
joints, mesh all parts of this subassembly, and perform a stress analysis using FEMAP/NASTRAN. Define
all properties (at your discretion) that you will need, in order to perform a static analysis, use [mm-t-s] SI
consistent units, and document all your work. Guidelines on setting up the FE model (preprocessing) and
on postprocessing the results, along with the questions to be addressed in this study are outlined in the
next pages.
Figure 1. Your CAD model ― Isometric View
ME 4060 Stress Analysis of a Car Suspension in FEMAP Final Project A (A-D)
Some Basic Guidelines on the FE Model Setup
1. This is an individual type of project (not a team project).
2. Make sure you work on the CAD model that you’ve been assigned: Scale the CAD model properly,
according to Table 1 below (where you will find your name). [Note: No credit will be earned when
working on a different CAD model or with the wrong dimensions]
Table 1. Car Suspension Dimensions ― Reference
Name SCALE FACTOR (w.r.t. Origin)
Amith, Zain 2.5 (in X,Y,Z) @ (0,0,0)
Anonuevo, Adrian Sean 3.0 (in X,Y,Z) @ (0,0,0)
Bill, Jenny Rin 4.5 (in X,Y,Z) @ (0,0,0)
Cappelletty, Tyler 5.0 (in X,Y,Z) @ (0,0,0)
Castro, Thomas Alan 6.5 (in X,Y,Z) @ (0,0,0)
Chavez, Jenn 7.0 (in X,Y,Z) @ (0,0,0)
Chen, Legolas 8.5 (in X,Y,Z) @ (0,0,0)
Cuevas, Shaun Mari Patrick Teves 9.0 (in X,Y,Z) @ (0,0,0)
Duong, Nghia 10.5 (in X,Y,Z) @ (0,0,0)
3. Review your CAD model: Identify all possible joints and remove secondary members that won’t
participate in the behavior of the simplified joint (e.g., the pin in a revolute joint along with its
circlips can be removed, bolts can be removed, bearings can be removed, etc.).
4. Defeature the geometry wherever possible (in order to obtain a better quality mesh). You can
then start meshing the geometry: Feel free to use any type of solid mesh (TET or HEX) you like,
but make sure the mesh density is such that the meshed bodies don’t deviate much from their
parent geometry. At the same time, be aware that the denser the mesh, the longer it would take
to perform an analysis.
5. Create all simplified joints using the technique we presented in class (based on our latest lab
activities), by employing rigid body elements and springs. [Note: No credit will be earned when
using any other type of joint or technique, other than those we learned in class. Touching or sliding
contact is not allowed; instead, you can use the equivalent planar/flat joint, if needed]
6. Employ glued contact among parts whose motion is expected to be prevented. For example, the
tire mounted on the wheel would both be candidates for glued contact; however, in this study,
we would completely discard/remove both the tire and the wheel from our FEA (to expedite the
analysis). Still, some of the parts in the shock-absorber can be glued.
2 | Max Repupilli
ME 4060 Stress Analysis of a Car Suspension in FEMAP Final Project A (A-D)
7. Enforce the constraints shown in Figure 2. Then, choose the magnitude of the loads shown, so
that the shock-absorber (shown in yellow and magenta) would contract visibly.
8. All work must be done in FEMAP/NASTRAN. [Note: No credit will be earned if using a different
FEA software]
Figure 2. Loads and Boundary Conditions
3 | Max Repupilli
ME 4060 Stress Analysis of a Car Suspension in FEMAP Final Project A (A-D)
Finite Element Analysis
Perform a static analysis in FEMAP/NASTRAN to determine:
a. The weight of the system using four different approaches (to be output by FEMAP).
b. The loads that each member is being transmitted at the joints locations (i.e., freebody
diagrams).
Questions
‒ Types of joints you’ve identified in your CAD model
‒ The weight of the system (outline four distinct approaches used to determine it)
‒ All Support Reactions
‒ All Internal Load at the joints
‒ Max displacement (along with its location and direction)
‒ Max VonMises Stress in solids (along with its location)
‒ Max Principal Stress in solids (along with its location)
Submission on CANVAS (by Sun, May 19)
1. A brief and simple report (on a .pdf, .docx, or .pptx format)…
a. Showing all assumptions made (thus, tables containing the material properties, the
BC’s chosen, the loads applied, etc.)
b. Showing the joints identified in your model (use an isometric view to pinpoint each)
c. Describing the analyses performed
d. Substantiating your answers by showing screenshots of your results (like contour plots,
diagrams, etc.).
2. The FE model (.modfem file) built in FEMAP.
3. The outputs (.f06 and .dat files) generated after running the NASTRAN analyses.
4 | Max Repupilli
