Control arm design for passenger bus with independent front suspension system

In this thesis, the design of the upper and lower control arms belonging to the domestic independent front suspension system, which is planned to be used in a passenger bus, are discussed. Based on the suspension system requirements provided by the vehicle manufacturer (OEM) and the design constraints within this system, the lower and upper control arms are designed in CATIA V5R26 software. At the same time, the connection elements of the wishbone group have been examined considering the construction requirements. Static finite element analysis studies were performed in ANSYS Workbench software by reference to the standard loading types given in the literature in order to determine the resistance of the control arms to the forces to be exposed under different road conditions. The obtained finite element analysis results, production methods for the control arms, cost, supplier constraints were evaluated separately and material selection was made. Experimental studies were carried out to obtain S-N curves for control arm materials. Material samples were produced and tensile and fatigue tests were conducted at Ege University Central Research Test and Analysis Laboratory Application and Research Center. The obtained S-N curves were transferred to the ANSYS program and fatigue analysis was performed by using the infinite life approach in the Fatigue tool interface. As a result of these studies, the final design of the control arms before prototype production was determined.