International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056

Volume: 04 Issue: 10 | Oct -2017 www.irjet.net p-ISSN: 2395-0072

DESIGN AND DEVELOPMENT OF H-FRAME WITH LATERAL LINK

SUSPENSION FOR AN ALL TERRAIN VEHICLE

Parag Borse1, Vaishnav Mayekar2, Nilesh Jain3

1,2,3 Department of Mechanical Engineering, Pimpri Chinchwad College of Engineering, Maharashtra, India .

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Abstract- All Terrain Vehicle (ATV) as defined by American and keep the tire perpendicular to the ground. This is
National Standards Institution ANSI as a vehicle that travels especially important for the outer tire because of the weight
on low pressure tires, which is used to handle any kind of transfer to this tire during a turn. This type of suspension
terrain it faces. The paper focuses on design of rear suspension requires hem joints for connecting the linkages. Between the
system for an ATV. The paper covers simulation, modelling and outboard ends of the arms is a knuckle with a spindle (the
analysis of suspension geometry. Suspension is designed such kingpin), hub, or upright which carries the wheel bearing
that it provides better handling and better comfort for an ATV. and wheel.

1. INTRODUCTION 1.2 Advantages of H-frame with Lateral Link

A vehicle suspension system is a linkage to allow the wheel This type of suspension carries the following advantages
to move relative to the body and some elastic element to over the other type of suspensions
support loads while allowing that motion.
 Better lateral load handling capacity.
Most practical vehicles have some form of suspension,  As this kind of suspension contains two linkages in
particularly when there are four or more wheels. the lateral direction, the suspension is capable of
handling large amounts of lateral loads which are
The primary functions of a suspension system are to: induced during cornering. When a vehicle is taking
turn a force equal to the centrifugal force is acted
 To support the vehicle weight upon the contact patch of the wheel, thus a moment
 To separate the vehicle body from road is induced in the suspension components.
disturbances, and  Thus one of the two linkages is in compression and
 To maintain the contact between the tire and the other is in tension.
road surface also  Better control over camber throughout the wheel
 To improve stability and ride comfort of the vehicle travel.
 Resist roll of the chassis.  The working of H-frame with lateral link is
equivalent to double wishbone type suspension
 React to the control forces produced by the tires-
system. The linkages form 4 bar linkages and the
longitudinal (acceleration and braking) forces,
articulation of each linkage can be controlled as per
lateral (cornering) forces, and braking and driving
the requirements simply by changing the lengths of
torques.
linkages and the positions of the pivot points.
1.1 H-frame with Lateral links  Better Anti-Squat properties.
 The H-frame can be mounted inclining backwards
The rear suspension was selected as H-frames with lateral thus during acceleration the forces generated due to
link, it consists of H-frame and also contains one link in weight transfer are taken by H-frame. [3]
lateral direction which is used to carry lateral load and also  Plunging of the shafts can be minimised easily.
controls camber through suspension travel. [1]  As this suspension geometry is equivalent to double
wishbone geometry, the plunging of shafts can be
The H-frame with camber link consists of the H-frame and minimised by following the ICR geometry which is
two links for controlling the camber throughout the used for minimising bump steer.
suspension travel and for carrying the lateral loads.
1.3 Design and Analysis
The suspension consists of upper and lower lateral arms.
The upper arm is usually shorter to induce negative camber The important properties of a suspension related to
as the suspension jounces (rises). When the vehicle is in a dynamics are the kinematic (motion) behaviour and its
turn, body roll results in positive camber gain on the outside response to the forces and moments that it must transmit
wheel. The outside wheel also jounces and gains negative from the tires to the chassis. In addition, other
camber due to the shorter upper arm. [1] The suspension characteristics considered in the design process are cost,
designer attempts to balance these two effects to cancel out

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 International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 04 Issue: 10 | Oct -2017 www.irjet.net p-ISSN: 2395-0072

weight, package space, manufacturability, ease of assembly,

and others

The main factors for the design of the rear suspension are
weight, functionality and cost. The rear suspension was
identified to be the H-frame, 1 lateral link per side, knuckle,
hub, tires and rims. The suspension was designed to
maximize travel without affecting other performance
parameters. It was required to have negative camber gain in
bump and positive camber gain in droop. The allotted weight
for this system is 15kg.

1.4 Objectives of suspension design

Fig-1: Effect of Roll Axis [5]
 To provide greater travel. An ATV has to handle
rough terrain for which it has to allow better To start with the suspension designs firstly the vehicle
absorption of the shocks during the changes in parameters such as wheel track, wheel base were defined
ground conditions. Thus to travel through larger according to the rules specified by SAE BAJA which states
bumps and ditches, the suspension system requires that “Maximum dimensions of vehicle should be 64 inches
greater amount of travel. width”.
 To reduce unsprung mass so as to have lesser
inertia loads, thus the response time of the Considering this overall width and the size of the tire and
suspension to changes in the track surface is wheel combination, the suspension must be designed such
minimized. This allows the tire to maintain constant that maximum width at the tire edge surfaces is not more
contact with the surface as much as possible. than 64 inches at ride height.
 To avoid bump steer. Table 1 shows the various vehicle dimensions decided.
 To provide better handling while cornering by
providing camber gain. Table -1: Vehicle Dimensions
 To minimize plunging of CV-joints in rear
suspension. This minimizes chances of popping out Vehicle dimensions at Rear
of the half shafts from gearbox. [3] ride height
Width 58 inches
1.5 Steps for Designing Suspension system Wheelbase 53 inches
Ground clearance 21 inches
The basic criterion to achieve better handling was to have
camber gain in roll. In other words, as the car corners, the The track width was kept smaller to aid in manoeuvrability.
goal is to gain negative camber at the outer wheels and to The wheel base was kept minimum to decrease the turning
gain positive camber at the inner wheels of the vehicle. radius. To maximize obstacle avoidance, a ground clearance
of 11 inches from the ground to the lowermost member on
By providing sufficient camber gain the wheels remain the chassis was chosen.
vertical to the ground even when the body rolls, which
provides better grip while cornering. Recessional wheel travel is also provided which accounts for
the longitudinal forces that arise during the vehicle
Also the roll centre of the rear suspension was kept higher approaches a bump.
than the roll centre in front to decrease over steering of the Table 2 shows various design parameters of the suspension.
vehicle.
Table -2: Suspension System Parameters
The roll centre has a significant impact on a suspension’s
steering response; moreover, there is a direct correlation Parameter Value
between roll centre location and over steer, under steer, or
Front Rear
neutral steer suspension behaviour depicted in Figure 17.
suspension suspension
Suspension travel in 6 inches 6 inches
Jounce
Suspension travel in 2 inches 2 inches
droop
Roll centre height 13.7 inches 10

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Camber 10 10

Toe in 00 00
Camber gain per 0.70 0.70
degree roll
Recessional wheel 1 inch 1 inch
travel
Stiffness (k) (N/mm) Variable Variable

Damper travel 6 inches 6 inches

1.6 Design of Suspension Geometry Fig-3: H-Frame

The suspension geometry was obtained by using

instantaneous centre method so as to have minimum bump
steer in front and minimum plunging of shafts in rear
geometry. The lengths of the wishbones, tie rods, H-frame,
Lateral link and half shaft were obtained from the geometry.
The Geometry obtained by using Instantaneous Centre
Method .

Fig-4: Rear Hub

Fig-2: Suspension Geometry (determination of link

lengths) AutoCAD Drawing

The mounting of the front suspension was made on nose.

The shock absorber was mounted on front bracing member.
The mounting of the rear suspension and shock absorber
was made on engine compartment members.
Fig-5: Rear Knuckle
1.7Design and Modelling of the Suspension Components

The components to be designed are as follows

 H-frame
 Lateral link
 Knuckle
 Wheel hub
 Shock absorber (Selection)

The various suspension components were modeled using uni

graphics software as shown below.

Fig-6: Rear Assembly

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 International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 04 Issue: 10 | Oct -2017 www.irjet.net p-ISSN: 2395-0072

1.8 Analysis of the Suspension Components Considering a fraction of centrifugal force acting on rear
wheels.
For analysing the components ANSYS software was used in Fr= 4307.73×0.5
which the components were analysed for combined loading =2153.86 N
of the forces. Then according to the results the changes were
made in the components so as to meet the objectives. While cornering the weight of the vehicle is transferred to
outer wheels.
Following loads were applied for analysing the suspension
components: Thus it can be assumed that the centrifugal force is
completely acting on the outer wheels.
The forces acting on them are Moment acting on suspension components
M=Fr ×r
1. Longitudinal forces: - These forces arise due to
braking and drive line forces acting on the =2153.86×11×0.0254
components. The drive line forces are mostly taken =602 Nm
by the H-frame and the braking forces are carried
by the wheel hub and the bearing carrier. 3) Longitudinal Forces:
2. Lateral forces: - When a vehicle is taking turn a The longitudinal forces arise due to braking action
force equal to the centrifugal force is acted upon the Mb =breaking moment = 161 Nm
contact patch of the wheel, thus a moment is
induced in the suspension components and this load Following loads were applied for analysing the rear
is carried by the camber links as well as the bearing suspension components.
carrier.
3. Vertical forces: - These forces arise due to the Table -3: Forces acting on Suspension Components
bumps in the ground. Usually 3g loads are acting on
the components in case of bumps.
DIRECTION FORCE/MOMENT
1.9 Calculations of Forces: LONGITUDINAL 161 Nm

1) Forces due to reaction from the ground: LATERAL 602 Nm

a) Forces due to self-weight: VERTICAL 3G N
F1=
b) Dynamic forces on suspension components is The calculated forces were the used to analyse the
considered to be 3 times the self-weight: components in Ansys. The Ansys results of H-frame, knuckle,
F2=3× F1 stub, hub, are shown in Figure19, 20, 21,22,23,24
Considering weight of vehicle = 220 kg
F2=6474.6 N

2) Forces arising while cornering:

While cornering centrifugal forces are acting on the vehicle &

to keep the vehicle stable reactions are acting in the opposite
direction at the contact patch of wheel. As the force is acting
at a distance equal to the radius of wheel, thus a moment is
acting on the suspension components due to lateral forces.
Let
M= moment acting on suspension components
R= radius of turn while cornering
r= radius of wheel
Fl=lateral forces/reactions at wheel
Fc=centrifugal force
Fr=radial force
Fc=
Fig-7: Rear Knuckle
=
=4307.7375 N

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alloy and weighs around 1.6 kg only. Fox suspension has 2

air chambers namely main chamber and evol chamber. Fox
stiffness varies with main chamber pressure and ride height
varies with pressure in evol chamber.

Fig-8: H-frame

Table -4: Results of FEA

Components σmax (MPa) Factor of safety

Front Hub 92.77 2.97 Photograph -1: Fox Shock Absorber
Front Knuckle 58.24 4.73
Lower wishbone 542.93 1.33
Stub axle 383.72 1.88
Rear knuckle 59.55 4.63

H-frame 428.69 1.6

1.10 H-frame and Specification:

Table -5: H-frame and wishbones Specifications

Material Mild Steel

Carbon % 0.4%

Cross-section Circular

Diameter 1”

Thickness 1.6 mm
Fig -9: Air spring curve Restoring force vs Travel
1.11 Problem faced: 1.13 Assembly of Parts
H-frame mounting brackets failed in shearing, because of After manufacturing of all the parts, assembly of the
misalignment of mounting bushes. manufactured parts was done finally. The process sheet for
the assembly is as following
1.12 Selection of Shock Absorber

Fox air suspension was selected which provides easy

adjustment of stiffness, ride height and rebound velocity.
The Fox air suspension also helped reducing the unsprung
mass with its light weight body made of 6061 aluminium

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Photograph -5: Suspension response over

Photograph -2: Assembly of rear hub and knuckle bumps

Photograph -3: Assembly of rear suspension

Photograph -6: Testing of suspension system
2. VALIDTING AND TESTING

Testing of the front and rear suspension was done for over 3. CONCLUSION
450km on the rough terrain. For almost 120km there were
no major failures experienced. The components of the suspension system are analysed in
ANSYS Workbench 14.0 software. Using Grid Sensitivity
Analysis the optimum mesh size for the components are
obtained.

The entire suspension geometry was simulated with the help

of suspension simulation software, which provides us with
the verification of suspension hard points.

The results obtained from simulation proves that the tyre

remains perpendicular to the ground surface during the
cornering of the vehicle, thereby providing better grip with
the help of sufficient camber gain.

The results obtained from simulation software also proves

that the toe change for the proposed geometry was
Photograph -4: Suspension response in minimum, thus minimizing the bump steer of the vehicle.
trenches The suspension hard points were so adjusted that the
plunging of drive shafts is minimized.

The total suspension travel is 8 inches; 6 inches in bump and

2 inches in droop.

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 International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 04 Issue: 10 | Oct -2017 www.irjet.net p-ISSN: 2395-0072

Thus the objective of designing a light weight and rugged

suspension system for an all-terrain vehicle is achieved.

4. REFERENCES

1) Auburn University “2010 Baja SAE Suspension”

2) John C. Dixon “Suspension Geometry And
Computations”
3) Nick Brookman “Baja SAE Rear Suspension Design” SAE
international, April 2007
4) PSG College of Engineering “Design Data”
5) Robert Casion“2007-08 WPI SAE Baja Vehicle”
6) Thomas d. Gillespie “Fundamentals of Vehicle Dynamics

5. BIOGRAPHIES

Parag Borse
A mechanical engineer from Savitribai
Phule Pune University. Prowess in
Suspension and manufacturing
processes.

Vaishnav Mayekar
A mechanical engineer from Savitribai
Phule Pune University.
Prowess in Rollcage and CAD/CAE

Nilesh Jain
A mechanical engineer from Savitribai
Phule Pune University.
Prowess in Drive shaft and
manufacturing process

Dhanraj Shinde
A mechanical engineer from Savitribai
Phule Pune University. Prowess in
steering systems and CAD/CAE

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