Suspension arms for a supercar
For an important car manufacturer we designed, tested and produced the suspension arms for their new Supercar. Our customer asked FRAP to develop a product which solved:
1- the highly demanded needs to reduce the weight compared to traditional solutions
2- the need to reach an extremely low and fluid rotational torque
To meet the first requirement, we chose an aluminum solution.
Aluminum weighs only one third of steel, under the same volume. Its application allows significant weight saving, in almost all mechanical applications. Actually, airplanes are 70% made of aluminum!
Another improvement was the ball joint, directly integrated into the arm, as a result of the machining process of the extremity of the arm itself.
To meet the second requirement and get an extremely low and fluid rotational torque of the integrated ball joint, we applied different solutions.
First of all, an accurate design of the structure and tolerances of all the components of the ball joint. Secondly, the design of the rotational torque starting from our deep knowledge of the materials under all conditions and temperatures of their use, including the lubricant grease. In this way, we could immediately identify both the most suitable materials and the heat & surface treatments, with the clear aim of meeting the high requirements demanded by the customer.
Finally, FEM analysis and fatigue tests validated the whole design process. In just 18 months we designed, tested and produced the first arms for the pre-series. Everything in full compliance not only with the highly demanding characteristics required, but also with the required timing.
