Lesson 5: Suspension System

           

           The suspension system is another vital part of an automobile. It absorbs shocks that are produced by obstacles on road. It always keeps car chassis above the ground up to a safe level and varies with category to which that automobile belongs. This also applies to RC cars. Off road RC cars have suspension system that is entirely different from that of on road. Following is a figure of typical front suspension system and there is not much differences between front and back systems, so here I will explain about only front system. In below showed figure parts in black colored rings difficult to fabricate but nothing is impossible. However we never tried to do so but we fabricated entire system except those parts. Usually organizers never demand to fabricate such complicated parts.

           

            A typical suspension system contains upper, lower suspension arms and shock stay or suspension support. We fabricated these parts by using 6mm thick aluminum sheets and we used a profile cutter to do so. I am not having more photographs of fabrication but having a plate that is left after complete fabrication and you can see it in upcoming pages.

  

Following are figures of those parts drawn by using CATIA V5 and we analysed their weak points during stress and strain analysis. We used this report to put holes at appropriate locations by using a drill machine once again I would like to state that this is really a difficult task to put holes on those tiny parts.If you don't know how handle drill machine in proper manner, then please approach professionals.

Front upper suspension arm

Front Lower suspension arms

Rear Upper suspension arms

Rear Lower suspension arms

    

                         Below is a photograph of plate that is left after fabrication of above stated parts.

     For fabrication of suspension support we did not used aluminium plate instead used a composite plate that is made up of nylone paper and thin sheet of aluminum, that is usually used in making electronic switch boards. And it is really easy to use profile cutter on it to give desired shape. Below you can see that part.

Suspension mount

After assembling all above parts, system looks as shown below. You can see that except suspensions, screws, differential system, connecting rods, wheel hubs and wheels, all other parts are made up of aluminium sheet.

             So this concludes topic. As stated earlier this is just a one design and you can develop your own one also. For this let me give you a tip, use a part that is used to connect door or window to their frames and can act as best solution for suspension arms. It is just only one suggestion and there are lot more present in your own brain also. Like this before going to design any part just have a look at your surroundings and that can help you a lot. And as usually dart me a mail if you have any doubts regarding RC cars at 

bpr890@gmail.com and best of luck for your races.

          Thanks and Regards

          Bharatesh Regoudar

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