ANSYS Mechanical Analysis for Baja SAE Suspension Using ANSYS Mechanical
Budget: $10 – $30 USD
FEA Validation of Baja SAE Double Wishbone Suspension Components Using ANSYS Mechanical
Project Overview
We are a senior mechanical engineering design team finalizing a high-performance, long-travel off-road vehicle (Baja style). The kinematic optimization of the double A-arm suspension has been successfully completed in OptimumKinematics.
We are now seeking an expert Finite Element Analysis (FEA) / Structural Simulation Engineer to conduct a comprehensive structural validation of the suspension components only (Upper/Lower A-Arms, Tie-Rods, and Knuckles/Uprights) using ANSYS Mechanical (Structural).
The chassis will not be included in the simulation model. Instead, chassis-side suspension mount joints will act as boundary constraints, and extreme dynamic operational forces will be applied directly through the wheel center/stub axle.
Please note that this task requires running the exact same simulation setup for two separate CAD files: the initial “Base Model” and the “Optimized Model”.
No report writing is required. The freelancer will only be responsible for delivering the resolved ANSYS project files, raw simulation data, and high-resolution plots. The final report will be authored by our team.
Vehicle & Design Specifications
Suspension Assembly Components to Analyze:
* Upper Control Arm
* Lower Control Arm
* Tie-Rod (Steering Link)
* Knuckle/Upright
Material:
AISI 4130 Chromoly Steel (Normalized Condition)
Material Properties:
* Yield Strength = 460 MPa
* Ultimate Tensile Strength = 700 MPa
* Poisson’s Ratio = 0.29
* Young’s Modulus = 205 GPa
Component Type:
Fabricated thin-walled tubular/plate suspension control arms with wall thickness between 1.5 mm and 2.0 mm.
Total Gross Vehicle Mass:
300 kg (including driver, powertrain, chassis, and sprung mass distribution)
Suspension Travel:
Total vertical wheel travel = 240 mm
(+120 mm jounce and -120 mm rebound from static ride height)
Scope of Work & Required Analyses
1. Static Structural Analysis (Multi-Step Loading at Extreme Suspension Positions)
The suspension linkages must be validated against four distinct extreme operational loading scenarios derived from the 300 kg vehicle mass.
The analysis should evaluate components at:
* Static Ride Height
* Maximum Jounce (Compression)
* Maximum Rebound
Scenario A: 6g Vertical Landing (Extreme Bump Impact)
Condition:
Simulates hard bottoming-out after a vertical drop or jump.
Loading:
Vertical force equivalent to 6g acceleration applied upward at the tire-ground contact patch or stub axle.
Acceleration:
6g = 58.86 m/s²
Total Force:
F = 300 kg × 58.86 m/s²
F = 17,658 N
Criteria:
* Von Mises stresses must remain below 460 MPa yield strength.
* Target Safety Factor (SF) > 1.5.
Scenario B: 4g Longitudinal Braking Impact
Condition:
Simulates maximum hard braking or front-wheel obstacle strike.
Loading:
* Longitudinal force = 4g
* Combined with normal vertical 1g load
Acceleration:
4g = 39.24 m/s²
Longitudinal Force:
F = 300 kg × 39.24 m/s²
F = 11,772 N
Applied rearward at the wheel center.
Scenario C: 2.5g Lateral Cornering Load
Condition:
High-speed cornering creating severe bending loads on control arms and knuckle.
Loading:
Lateral force equivalent to 2.5g acceleration.
Acceleration:
2.5g = 24.52 m/s²
Lateral Force:
F = 300 kg × 24.52 m/s²
F = 7,356 N
Applied at the tire contact patch center.
Scenario D: Combined Loading
Condition:
Hard cornering while striking a bump.
Loading:
* 2.5g lateral load
* 4g vertical load
Combined vector loading applied to the outside wheel assembly.
2. Boundary Conditions & Boundary Setup
Supports:
The inner pivots of the Upper and Lower A-Arms (where they connect to the chassis) must be constrained using one of the following approaches:
* Revolute Joints
* Cylindrical Supports
* Localized Fixed Supports
The objective is to properly isolate the suspension mechanism while representing realistic suspension articulation.
Shock/Damper Mount:
The shock absorber mounting location on the lower control arm must be represented using either:
* Directional spring/damper elements
or
* Equivalent force vectors corresponding to maximum damper force at full bump compression
3. Eigenvalue Buckling Analysis
Objective:
Evaluate the buckling resistance of suspension members under severe braking conditions (Scenario B).
This is considered a critical failure mode for suspension links and steering rods operating in compression.
Requirement:
Run an Eigenvalue Buckling Analysis linked to the static braking load case.
Track:
* First buckling mode
* Second buckling mode
* Third buckling mode
Acceptance Criterion:
First Buckling Load Multiplier > 1.5
Technical Requirements & Deliverables
Geometry Handling
We will provide finalized CAD files in:
* STEP (.stp)
* IGES (.igs)
for both:
* Base Model
* Optimized Model
Meshing Strategy
Use high-quality solid and/or shell meshing.
Apply strict local mesh refinement (1 mm to 2 mm element size) at:
* Ball joint housings
* Shock mount tabs
* Tube-to-tube welded intersections
* Bracket radii
* Stress concentration regions
Final Deliverables (For Both Base and Optimized Models)
1. Fully operational and resolved ANSYS Workbench project files (.wbpz)
2. Raw simulation result files
3. High-resolution contour plots including:
* Von Mises Stress
* Total Deformation
* Factor of Safety
* First Three Buckling Mode Shapes
Candidate Requirements
* Proven experience in automotive suspension FEA, motorsport engineering, or mechanical linkage simulation.
* Advanced proficiency in ANSYS Mechanical Workbench (Static Structural and Buckling modules).
* Strong understanding of AISI 4130 Chromoly Steel behavior.
* Experience with thin-walled tubular structures and welded joint stress analysis.
Please provide:
* A quotation
* Estimated project timeline
* Brief portfolio examples of suspension, linkage, or motorsport-related simulations completed in the past.
Project Overview
We are a senior mechanical engineering design team finalizing a high-performance, long-travel off-road vehicle (Baja style). The kinematic optimization of the double A-arm suspension has been successfully completed in OptimumKinematics.
We are now seeking an expert Finite Element Analysis (FEA) / Structural Simulation Engineer to conduct a comprehensive structural validation of the suspension components only (Upper/Lower A-Arms, Tie-Rods, and Knuckles/Uprights) using ANSYS Mechanical (Structural).
The chassis will not be included in the simulation model. Instead, chassis-side suspension mount joints will act as boundary constraints, and extreme dynamic operational forces will be applied directly through the wheel center/stub axle.
Please note that this task requires running the exact same simulation setup for two separate CAD files: the initial “Base Model” and the “Optimized Model”.
No report writing is required. The freelancer will only be responsible for delivering the resolved ANSYS project files, raw simulation data, and high-resolution plots. The final report will be authored by our team.
Vehicle & Design Specifications
Suspension Assembly Components to Analyze:
* Upper Control Arm
* Lower Control Arm
* Tie-Rod (Steering Link)
* Knuckle/Upright
Material:
AISI 4130 Chromoly Steel (Normalized Condition)
Material Properties:
* Yield Strength = 460 MPa
* Ultimate Tensile Strength = 700 MPa
* Poisson’s Ratio = 0.29
* Young’s Modulus = 205 GPa
Component Type:
Fabricated thin-walled tubular/plate suspension control arms with wall thickness between 1.5 mm and 2.0 mm.
Total Gross Vehicle Mass:
300 kg (including driver, powertrain, chassis, and sprung mass distribution)
Suspension Travel:
Total vertical wheel travel = 240 mm
(+120 mm jounce and -120 mm rebound from static ride height)
Scope of Work & Required Analyses
1. Static Structural Analysis (Multi-Step Loading at Extreme Suspension Positions)
The suspension linkages must be validated against four distinct extreme operational loading scenarios derived from the 300 kg vehicle mass.
The analysis should evaluate components at:
* Static Ride Height
* Maximum Jounce (Compression)
* Maximum Rebound
Scenario A: 6g Vertical Landing (Extreme Bump Impact)
Condition:
Simulates hard bottoming-out after a vertical drop or jump.
Loading:
Vertical force equivalent to 6g acceleration applied upward at the tire-ground contact patch or stub axle.
Acceleration:
6g = 58.86 m/s²
Total Force:
F = 300 kg × 58.86 m/s²
F = 17,658 N
Criteria:
* Von Mises stresses must remain below 460 MPa yield strength.
* Target Safety Factor (SF) > 1.5.
Scenario B: 4g Longitudinal Braking Impact
Condition:
Simulates maximum hard braking or front-wheel obstacle strike.
Loading:
* Longitudinal force = 4g
* Combined with normal vertical 1g load
Acceleration:
4g = 39.24 m/s²
Longitudinal Force:
F = 300 kg × 39.24 m/s²
F = 11,772 N
Applied rearward at the wheel center.
Scenario C: 2.5g Lateral Cornering Load
Condition:
High-speed cornering creating severe bending loads on control arms and knuckle.
Loading:
Lateral force equivalent to 2.5g acceleration.
Acceleration:
2.5g = 24.52 m/s²
Lateral Force:
F = 300 kg × 24.52 m/s²
F = 7,356 N
Applied at the tire contact patch center.
Scenario D: Combined Loading
Condition:
Hard cornering while striking a bump.
Loading:
* 2.5g lateral load
* 4g vertical load
Combined vector loading applied to the outside wheel assembly.
2. Boundary Conditions & Boundary Setup
Supports:
The inner pivots of the Upper and Lower A-Arms (where they connect to the chassis) must be constrained using one of the following approaches:
* Revolute Joints
* Cylindrical Supports
* Localized Fixed Supports
The objective is to properly isolate the suspension mechanism while representing realistic suspension articulation.
Shock/Damper Mount:
The shock absorber mounting location on the lower control arm must be represented using either:
* Directional spring/damper elements
or
* Equivalent force vectors corresponding to maximum damper force at full bump compression
3. Eigenvalue Buckling Analysis
Objective:
Evaluate the buckling resistance of suspension members under severe braking conditions (Scenario B).
This is considered a critical failure mode for suspension links and steering rods operating in compression.
Requirement:
Run an Eigenvalue Buckling Analysis linked to the static braking load case.
Track:
* First buckling mode
* Second buckling mode
* Third buckling mode
Acceptance Criterion:
First Buckling Load Multiplier > 1.5
Technical Requirements & Deliverables
Geometry Handling
We will provide finalized CAD files in:
* STEP (.stp)
* IGES (.igs)
for both:
* Base Model
* Optimized Model
Meshing Strategy
Use high-quality solid and/or shell meshing.
Apply strict local mesh refinement (1 mm to 2 mm element size) at:
* Ball joint housings
* Shock mount tabs
* Tube-to-tube welded intersections
* Bracket radii
* Stress concentration regions
Final Deliverables (For Both Base and Optimized Models)
1. Fully operational and resolved ANSYS Workbench project files (.wbpz)
2. Raw simulation result files
3. High-resolution contour plots including:
* Von Mises Stress
* Total Deformation
* Factor of Safety
* First Three Buckling Mode Shapes
Candidate Requirements
* Proven experience in automotive suspension FEA, motorsport engineering, or mechanical linkage simulation.
* Advanced proficiency in ANSYS Mechanical Workbench (Static Structural and Buckling modules).
* Strong understanding of AISI 4130 Chromoly Steel behavior.
* Experience with thin-walled tubular structures and welded joint stress analysis.
Please provide:
* A quotation
* Estimated project timeline
* Brief portfolio examples of suspension, linkage, or motorsport-related simulations completed in the past.