Designed and optimized the front suspension geometry of the Mk. 6 car. I chose the nodes of all of the suspension members to achieve the performance characteristics we desired and improve on the design of our Mk. 5 car. After choosing the geometry of the suspension I moved on to designing the front uprights. Based on the location of the a-arms, our desired toe/camber, our wheel hub, bearings, sensor munts, and brake calipers I cadded the uprights in Solidworks. I made the toe of the car adjustable by putting a shim between the steering clevis and the main upright. Additionally, I made sure in the design of the upright that there would be enough space for wrenches during assembly and that the part would be manufacturable by a CNC shop. After the preliminary design I used a topology FEA study to help with light weighting and then did static studies to ensure the upright would be strong enough. After the design phase of the project, I worked to make drawings for the parts, and then get them manufactured and assembled onto the car.
I worked to get the uprights machined at a CNC shop. Here is one of the completed ones!
Assembled front suspension
I machined the steering clevis's myself on a manual Mill