Design and Analytical Study to Improve the Ingredients of the 2012 Honda Accord's Double Wishbone Suspension System

Encompass the necessary aspects of vehicle suspension systems and providing a soft estimate for their study and design [3], FEA was performed on the sample after it was sketched in the solid works software, followed by simulation in MATLAB and FEA in the Ansys program. Two theories of FEA were investigated, the first of which is the burden analysis of DWB as well as jerk absorbent yields up during exhaustion life as well as the concluding safety factor while a disfiguration. The model dissection was used to gain natural indecisions [4]. CATIA and Solid Works' design, along with ANSYS' analysis and MSC ADAMS' investigation of the suspension system's simulation, reduced the car's authority while improving its appearance [5]. SimMechanics and Simulink software toolboxes were used to develop a simulation of the quarters vehicle's double wishbone suspension [6]. CATIA software was used to prepare and analyze the pattern, calculate the stance for the center of gravity, and determine the roll center for a perfectly consistent, comfortable ride [7]. One can create a new arrangement. In this study, a unique disposition can reduce installation authority by 25%, and an additional 20% of that authority is available for additional orders. By adjusting the knuckle geometry, additional work is done to limit the variety of chamber angles [8]. investigated the creation and use of five popular suspension systems [9]. A simulation study was carried out to investigate the effect of the dynamic parameters of the suspension system [10]. discusses a variety of suspension system characteristics as well as the contributions made by various academics in this field [11]. provided an assessment of the overall spatial model of all these suspension systems' location kinematics [12]. An efficient numerical method is suggested for the kinematic analysis of the double wishbone suspension [13]. The study aims to offer a comprehensive finite element model of the dynamic behavior of the double wishbone vehicle suspension system with consideration for link flexibility [14]. Kinematic dissection took advantage of the current state; it was calculated that summation regarding aberration could be clearly minimized by choosing a suitable un-dive angle and that, through CAD software dissection, an abeyance method should be periodically repainted as dimensions, trends, and hard points change [15]. layout and analysis of wishbones, dampers, bell crank, and push rod, which includes all layouts, calculations, and applications of various features in elements, led to the creation of the ideal design with a high level of safety and minimal component stress [16]. Analysis showed that AISI4130 is the best material for A-arm items, and that this pattern requires pipes with an outer diameter of 1 inch and a thickness of 2 mm [17]. determined the component geometry and material properties as well as the system loads [18]. offers the following recommendation for a useful and affordable back suspension system: two links are found on a trailing arm [19]. The purpose of the paper's summary is to create a formula student car with enhanced steering control which also helps with twisting analysis of the suspension [20]. Comparing the proposed suspension system to three other previously created suspension systems [21]. It is suggested to synthesize the car suspension system using integrated kineto-dynamic analysis [22]. Explanation of the full specifications and pictures of the 2012 Honda Accord [23].

4.1 The growth strategy

In the creation of the entire system, which also is carried out in two stages, the verification or evaluation of the system happens that after mechanical creation of the system.

The following actions were taken as the system was being designed:

Part A: Mechanical design

1. Decide on the type of suspension system to be employed.

2. Determine the basic parameters, such as wheelbase, track width, as well as the centre of gravity, in addition to height, tyres, wheels, or other suspension adjustments.

3. For the design, make knuckles and wishbones.

4. Springs for layout Part.

Part B: The system has been tested.

1. ANSYS WORKBECH2021R2 or a similar analytical package should be used to carry out a system's feasibility and safety assessment.
2. Testing that occurs that after system has been mounted on the automobile and driven in a variety of settings [8].
3. Finding the ideal balance between the competing goals of passenger comfort and traction in suspension system layout is consequently an art form [9]. The vehicle's manoeuvre ability safety is controlled by the suspension system [10]. A kind of the double A-arm suspension known as the DWB suspension Figure 1 also goes by the titles short-long arms (SLA) suspension and long arm (LA) suspension. [12]. Although more expensive than the beam type suspension system, a wishbone suspension is also lighter [9]. The most economical choice is the double wishbone suspension [13].

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Figure 1. Double wishbone suspension system

4.1.1 Various types of suspension systems

A- wishbone suspension system.

B- macpherson strut suspension system.

C- rigid suspension system [11].

4.2 Honda accord 2012

4.2.1 Summary of Honda accord 2012

A fantastic used midsize automobile choice is the 2012 Honda Accord shown in Figure 2. Although the cargo is on the tiny side, the cabin is rather roomy, and it survived all safety tests and obtained an above-average grade for dependability. The Accord's interior actually resembles that of a large automobile more than a medium one. By providing more powertrain choices and more agile handling, the 2012 Accord exceeds the majority of rivals in terms of performance. High grades for safety were given to the 2012 Honda Accord. The sedan got the top score of Good in each of the Insurance Center for Highway Safety's four crash tests. The 2012 Accord scored a perfect five stars in each of the three crash tests conducted by the Highway Traffic Safety Administration. It also achieved five stars for overall safety. The IIHS did not test the 2012 Honda Accord coupe, although the NHTSA gave it 5-star rating for rollover resistance. The 2012 Honda Accord makes use of the advantages of a high-end chassis design to provide pleasant and elegant handling dynamics. A world-class ride and performance on winding roads, lengthy expanses of major highway, and bad weather are provided by a double-wishbone forward suspension as well as a multi-link rear suspension. With this independent suspension system, the car's ride comfort, traction, and stability are all increased while the amount of unsprung mass is decreased [14]. The ability to drive in the snow is improved, and more unpaved roads are accessible with a six-inch ground clearance. Four-wheel disc brakes, front and back stabilizer bars, and electronic stability control, sometimes referred to as Vehicle Stability AssistTM (VSATM), are all included as standard equipment.

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Figure 2. Honda accord 2012 [23]

4.2.2 General vehicle characteristics

When considering a vehicle's handling and wheel travel capabilities, its suspension system is of utmost importance. Additionally, the hub and knuckle are designed using the results of a suspension geometry study to determine the various geometry angles [16]. Fundamental suspension geometry can be used to calculate wheel travel and grip conditions, but for more extreme situations, a FEA analysis will be needed. The calculation of the stresses caused by the excessive displacements caused by cornering is the main goal of this analysis utilizing finite elements. A vehicle's suspension system is exposed to a variety of stressors as a result of various road and driving conditions but rounding turns and driving over bumps create the most severe strains and pose the biggest threat to the vehicle's capability to keep its ability to manage the road. This study will look at the scenario involving turning at high speeds. As a result, Table 1 offers a summary of the vehicle characteristics that are used in determining the loads exerted on the suspension system [18].

4.2.3 Purposes of the suspension design

As the automotive suspension system was being developed, the major design objective was to maximize the effectiveness of a passenger's vehicle's ride comfort [22]. Suspensions are made to maintain a greater portion of tire in contact with the ground, which enhances the handling of the car [15]. If the suspension were ideal, it would be capable of lowering the car's chassis and bring its parts closer to the ground [20]. To isolate the vehicle's chassis from road vibrations is one of a suspension system's primary functions [21].

The following are the primary objectives of a suspension system's design:

A. To increase the connection patch and, thus, handling by minimizing variations of camber and toe even as wheel rotates.

B. To lessen unsprung mass so the vehicle can perform better and have better traction on rocky terrain [19].

6.1 Analysis of wheel

Utilizing ANSYS software, the static analysis of the wheel is examined, and the sample is designed using Solidworks2022. Considerations for the analysis of a wheel include braking force, cornering force, gravitational forces, and initially applied Cornering force is determined via vertical load as well as frictional force (Eq. (2,3). in the Y and Z axes) and braking force is determined by both. In the Y and Z axes as Eq. (6).and as Eq. (7). assess centrifugal force in the Y axis, Eq. (10). and establish support at the point where the knuckle and wheel make contact.

6.1.1 Results of simulation with titanium alloy wheel

First, we calculated the equivalent von Mises stress distribution, deflection/deformation, and safety factor employing titanium alloy utilizing a combined simulation program, Safety factor of titanium alloy shown in Figure 3, Equivalent stress of titanium alloy shown in Figure 4.

The results are displayed below:

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Figure 3. Safety factor of titanium alloy wheel

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Figure 4. Equivalent stress of titanium alloy wheel

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Figure 5. Safety factor of Al6061wheel

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Figure 6. Equivaent stress of AL6061 wheel

6.1.2 Results of simulation with Al6061 wheel

Then, using the AL6061 wheel material, we ran a simulation to calculate the safety factor, equivalent von Mises stress distribution, and deflection/deformation. The results are summarized as follows, Safety factor of Al6061 shown in Figure 5, Equivalent stress of AL6061 shown in Figure 6, Scheme of equivalent stress titanium alloy&Al6061wheel shown in Figure 7, Scheme of equivalent elastic strain titanium alloy&Al6061wheel shown in Figure 8.

6.1.3 Schemes of equivalent (stress, strain) wheel

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Figure 7. Scheme of equivalent stress titanium alloy&Al6061wheel

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Figure 8. Scheme of equivalent elastic strain titanium alloy&Al6061wheel

6.2 Analysis of knuckle

ANSYS software is used to analyze the static analysis of the knuckle, and the sample was also designed using Solidworks2022. Several other forces are also at playas Eq. (11) and as Eq. (12) such as the loads on the knuckle hub in the X, Y, and Z directions, as well as braking force, the moment, a lateral force, a steering force, as well as the loads in the lateral direction. Figures, which show the following findings from the analyses, are numerous and include:

6.2.1 Simulation with Al6061 knuckle

We started by simulating Deflection/Deformation, equivalent von Mises Stress Distribution, and Safety Factor together using Al6061 material. The conclusions are summarized as follows. Safety factor of Al6061shown in Figure 9, Equivalent stress of Al6061shown in Figure 10.

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Figure 9. Safety factor of Al6061 knuckle

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Figure 10. Equivalent stress of Al6061knuckle

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Figure 11. Safety factor of aluminum alloy knuckle

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Figure 12. Equivalent stress of aluminum alloy knuckle

6.2.2 Simulation with Aluminum Alloy knuckle

The simulation of combined deflection/deformation, equivalent Von Mises stresses distribution, and safety factor was then carried out using Aluminum Alloy material. These are the results. Safety factor of aluminum alloy shown in Figure 11, Equivalent stress of aluminum alloy shown in Figure 12, Scheme of equivalent stress aluminum alloy&Al6061 knuckle shown in Figure 13, Scheme of equivalent elastic strain aluminum alloy&Al6061knuckle shown in Figure 14.

6.2.3 Schemes of (stress, strain) knuckle

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Figure 13. Scheme of equivalent stress aluminum alloy&Al6061 knuckle

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Figure 14. Scheme of equivalent elastic strain aluminum alloy&Al6061knuckle

6.3 Analysis of wishbone

The layout was created using Solidworks2022, then it was subjected to an analysis using Ansys2021R2, and finally two loads were imposed to the top arm and the lower arm as Eq. (8) and as Eq. (9).

6.3.1 Simulation with steel 1020 of wishbone

Following that, steel1020 was used as the material for the integrated simulation for deflection/deformation, equivalent Mises stress distribution, as well as safety factor. Safety factor of AISI1020 that shown in Figure 15, Equivalent stress of AISI1020shown in Figure 16.

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Figure 15. Safety factor of AISI1020 wishbone

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Figure 16. Equivalent stress of AISI1020 wishbone

6.3.2 Simulation with AISI4140 wishbone

Following that, AISI4140 was used as the material of choice for the simulation that included deflection/deformation, equivalent Mises stress distribution, as well as safety factor. The repercussions include Safety factor of AISI4140 shown in Figure 17, Equivalent stress of AISI4140shown in Figure 18, Scheme of equivalent stress AISI1020&AISI4140 shown in Figure 19, Scheme of equivalent elastic strain AIS4140&AISI1020 wishbone shown in Figure 20.

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Figure 17. Safety factor of AISI4140wishbone

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Figure 18. Equivalent stress of AISI4140wishbone

6.3.3 Schemes of (stress, strain) wishbone

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Figure 19. Scheme of equivalent stress AISI1020&AISI4140 wishbone

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Figure 20. Scheme of equivalent elastic strain AIS4140&AISI1020 wishbone

The Altinbas University funded this research.