Suspension Mounts

Cal Poly Racing -Formula SAE - Suspension Subsystem

Overview

This project involved redesigning a structural rocker plate to improve strength, stiffness, manufacturability, and packaging within updated vehicle kinematics and aerodynamic constraints. The new design lowers the overall profile to minimize interference with the aero fairing and reduces one support arm to fit the revised geometry. Design improvements address prior fitment issues while simplifying the overall plate configuration. Emphasis was placed on structural integrity in bending, proper bearing retention, and efficient manufacturing using CNC processes and waterjet cutting

 Figure 1. Suspension plate design

Mechanical Design

The plate was designed using Aluminum 7075 (KT1.6) for high strength-to-weight performance. Support members were given an L-profile to improve bending stiffness, and material was removed through slotted pockets for mass optimization. Minimum internal and external radii were defined to match tooling constraints

 Figure 2. Plate cross section

Bearing holes were chambered for a P7/h6 press fit to correct prior looseness. A flange nut applies preload to the bearing inner race, with positive retention provided by a pinned rocker bung (not modeled)

Manufacturing includes waterjet rough cutting (0.25 hr), CNC milling with stabilizing tabs (2 hrs), and tab removal (0.5 hr)

 Figure 3. Bung assembly cross section

The updated design improves stiffness in bending while reducing overall mass and profile height. Press-fit tolerances and preload features correct previous bearing fit issues. The simplified geometry enhances manufacturability and structural reliability within packaging constraints

Finite Element Analysis

Updates coming soon