Composite Control Arm Design: A Comprehensive Workflow

Lightweighting is an increasingly popular topic in the automotive world as a means of increasing efficiency as well as performance. Lighter vehicle weights can be achieved by optimizing designs, utilizing higher performance construction methods, or changing product objectives and requirements. In an effort to avoid the latter, automotive companies are dedicating increasing amounts of resources towards the first two options. As more areas of the vehicle are being lightened, previously overlooked parts, such as suspension members, become more appealing targets. The relative advantages of lightweighting on different areas of a vehicle is investigated and the benefits of unsprung mass reduction versus sprung mass reduction is determined. Composite optimization techniques are utilized in applying carbon fiber reinforced polymer to vehicle suspension design, creating a hypothetical CFRP front upper control arm for an Audi R8. Tools are created to allow these phases to be completed rapidly, thus setting up a blueprint for a full workflow, from engineering request to product delivery, which can be applied to different vehicles and customer requests.