Design Process

The computer simulations of the Sacli suspension were done on a 2D model with separate front and rear wheel pairs.  The simulation didn’t include the tire behavior, steering and caster.  The tire was assumed to be rigid and the simulation was only used to predict camber results for the initial prototypes.

It should be noted that computers with much higher computing power and matching software would have allowed for the tire behavior to be included in the simulation model as well as other factors.  This would have lead to more accurate simulation of the system.  However, the cost of such computers and software would have also exceeded the cost of implementing the design on a few prototype cars and considering our budget and goals, we decided to follow the testing oriented path.

We used Solidworks to model the suspension system and Cosmos Motion to simulate it.  We used the simulation results to predict the camber results of the suspension system and rest of the design model was completed based on conventional suspension design knowledge.  We then built the suspension components needed for the systems and bolted the systems on existing FSAE cars for testing.  The simulation results were satisfactory where other factors such as steering, caster, yaw and etc. didn’t play a major role.