Strength Analysis of a New Upper Arm Design for Semi-Active Suspension System during Cornering

This study investigates the structural performance and design optimisation of a novel upper arm component in a semi-active suspension system, particularly under cornering conditions. A three-dimensional model was developed using SolidWorks, and structural analysis was conducted through the finite element method (FEM) utilizing ANSYS Workbench. The component material, AISI 4140 (EN-19) alloy steel, was selected due to its high yield strength and fatigue resistance. Simulation scenarios were based on real-world loading conditions of the Toyota FT86. The results indicate that the optimised upper arm design reduces component mass by approximately 14.3%, while maintaining structural integrity with Von Mises stress and deformation values well within allowable limits. The findings highlight the potential of FEM-based optimisation in enhancing vehicle dynamics through weight reduction and improved suspension response.