Structural and multibody analysis of a hypercar suspension components

This paper focuses on the analysis and design of components for the front suspension of a high-performance vehicle. The study is based on a real case in collaboration with Danisi Engineering, a company specializing in vehicle chassis components located in Nichelino (TO). The thesis, conducted in the company's engineering department, centers on structural analysis and modeling of three fundamental suspension components. The thesis is structured as follows: •??The first chapter provides a brief yet comprehensive overview of mechanical design and its key processes. •??The second chapter introduces the subject of study ‘the push-rod suspension’ offering a detailed overview of its main components and their physical characteristics. •??Chapters 3, 4, and 5 constitute the theoretical foundation for the tools adopted in the thesis project. Specifically, the third chapter is dedicated to exploring topology optimization, delving into its dynamics. In parallel, the fourth chapter addresses the fundamental principles of component modeling. Subsequently, the fifth chapter provides a brief overview of finite element analysis, contributing overall to the methodological basis of the study. •??The chapters, 6, 7, 8 and 9 illustrate the various stages of designing the three examined components: UCA, rocker and pushrod. Several solutions are proposed, subject to in-depth analysis and detailed discussion, including a comprehensive comparison regarding structural analysis, modeling, and constraint types. This aims to highlight the various advantages and disadvantages of each solution. This thesis aims to explore the field of automotive engineering through technical-scientific approach, providing meaningful contributions to the optimization of high-performance vehicle suspensions.