Design Improvement of MacPherson Strut Suspension System for Lighter Vehicle

This paper presents a design of a MacPherson strut suspension system for Bajaj Qute four-wheeler small vehicles. Data collection was done using different methods. Then, CAD modelling of the structure was made by using the data recorded from the existing vehicle suspension system. Then, the design of each component of MacPherson strut and existing suspension system was made using CATIA V5 software. Also, an analytical analysis was performed for analysis of the improved suspension system for the required results and FEA was done with ANSYS. The new models become safe than the existing in all aspects. So, the problem in the lateral direction which is flexible camber curve is solved, because the MacPherson suspension system has good camber curve not as flexible as other suspension system and also the stress in the existing system leads the system to have flexible camber; this is corrected in the new model. Also, the steering arm position is corrected to the middle of the knuckle to balance the steering force distribution. The vehicle also has lower ground clearance which is 180 mm when the vehicle is unloaded; with this ground clearance, it is difficult to drive in unpaved road. So, in this design, the ground clearance of the vehicle is increased to 220 mm. Therefore, the vehicle can be driven in all road conditions. It is found that as per the analysis done, the newly designed MacPherson suspension system is safe and performing better than the existing system.