International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 02 Issue: 07 | Oct-2015 www.irjet.net p-ISSN: 2395-0072 © 2015, IRJET ISO 9001:2008 Certified Journal Page 759 Design, analysis of A-type front lower suspension arm in Commercial vehicle Mr. Balasaheb Gadade 1 , Dr. R.G.Todkar 2 1 ME-Mech/ Design appearing, Annasaheb Dange College of Engineering, Ashta, India 2 Sr. Prof. Annasaheb Dange College of Engineering, Ashta ,India ------------------------------------------------------------------***----------------------------------------------------------------- Abstract: In this project work mainly focused on the finite element based stress analysis of A – Type lower suspension arm. The main objective of this study is to calculate working life of the component under static loading. The A – Type lower suspension arm was developed by using CAD software. Actual model was manufacture as per Design by using AISI 1040 material. The finite element modeling and analysis was performed by using HYPERMESH software. Mesh was created with 10 node tetrahedral element. A simple design approach was used to calculate effect of stresses on A – Type lower suspension arm element under static loading condition. After manual calculations a modern computational approach based on FEA for integrated durability assessment in an automotive lower suspension arm component is presented. The experimental work includes validation of the FEA results with actual testing of the model under stress. This is carried out with computerized universal testing machine (UTM) of 25 ton capacity. After trails it is seen that theoretical results agrees with the actual test experiments. Form calculations the maximum value of static load acting on the wheel of the automobile is 5000N. FEA analysis or software calculations gives maximum stress at contact point with wheel hub is about 280 MPa, and actual experimental tests gives maximum stress value of 254 MPa. This shows the fitness of the model designed under actual working conditions. Keywords – A-type lower suspension arm1; AISI 1040 material2; Static load condition3; Ride comfort4; Static analysis5; Suspension system6; maximum stress areas6. I. Introduction In the automotive industry, the riding comfort and handling qualities of an automobile are greatly affected by the suspension system, in which the suspended portion of the vehicle is attached to the wheels by elastic members in order to cushion the impact of road irregularities. Suspension arm is one of the main components in the suspension systems. It can be seen in various types of the suspensions like wishbone or double wishbone suspensions. Most of the times it is called as A-type control arm. It joins the wheel hub to the vehicle frame allowing for a full range of motion while maintaining proper suspension alignment. Uneven tire wear, suspension noise or misalignment, steering wheel vibrations are the main causes of the failure of the lower suspension arm. Most of the cases the failures are catastrophic in nature. Hence, it is reported that the structural integrity of the suspension arm is crucial from design point of view both in static and dynamic conditions. Finite Element Method (FEM) gives better visualization of this kind of the failures. In this paper we discuss about static analysis of lower suspension arm [1]. II. Suspension system The primary function of the suspension system of the vehicle should fulfill pretentious requirements about stability, safety and maneuverability. The suspension system of the vehicle performs multiple tasks such as maintaining the contact between tires and road surface, providing the vehicle stability, protecting the vehicle chassis of the shocks excited from the uneven road surfaces, etc. This system is the mechanism that physically separates the vehicle body from the wheels of the vehicle. The suspension system will consider ideal if the vehicle body isolate from uneven road and inertial disturbances associated during situation of cornering, braking and acceleration. III. Types of the suspension system The suspension system is always derived by some mechanical way. Generally speaking, the designs of