FEA-Based Analysis of Front Control Lower Arm in Automotive Suspension

The front control lower arm (LCA) is a pivotal component in an automotive suspension system, responsible for maintaining vehicle stability, handling, and overall comfort. This study delves into the structural integrity and performance of the LCA using advanced Computer-Aided Design (CAD) modeling and comprehensive Finite Element Analysis (FEA). The CAD model was meticulously developed in Creo and exported to ANSYS for detailed simulation. The FEA results revealed significant insights into the stress distribution, deformation patterns, and fatigue life of the control arm under realistic operational conditions. The analysis identified high-stress concentrations near the top mounting point, marking these regions as critical areas that necessitate design modifications to prevent potential failures. Specifically, the maximum equivalent (von-Mises) stress observed was 208.89 MPa, which is near the material’s yield strength, indicating a high likelihood of structural failure under prolonged stress. Additionally, the maximum total deformation was found to be 0.4218 mm, occurring at the same critical regions as the high-stress concentrations. This deformation pattern was smooth and well-distributed, suggesting a structurally sound design despite the stress vulnerabilities. Fatigue life predictions showed considerable variability, with the highest life expectancy exceeding 6.3 million cycles and the lowest life around 15,649 cycles in the high-stress areas. This correlation between stress concentration and reduced fatigue life underscores the necessity for targeted design improvements. By enhancing these critical areas, the overall durability and performance of the LCA can be significantly improved. This research provides a detailed methodology for evaluating the LCA’s structural performance, offering valuable insights into potential design enhancements. The study’s findings are crucial for automotive engineers and designers aiming to optimize suspension components for better reliability and longevity. The use of CAD modeling and FEA in this context demonstrates the importance of these tools in modern engineering, enabling precise simulations and accurate predictions that guide the design process. Future work will focus on implementing the suggested design modifications and validating their effectiveness through experimental testing and further simulation.