Enhancing Fuel Efficiency in LCVs through Structural Optimization of Suspension Components

Abstract

The most important component in vehicle is a suspension system, which directly affects the safety, performance andnoiselevel. The unsprungmassisthemassof the suspension components whichisdirectlyconnected tothem, rather thansupportedbythesuspension.High unsprungweightexacerbates issues like wheel control, ridequality and noise. Unsprung weight includes the mass of components such as the wheel axles, wheel bearings, wheel hubs, springs,shockabsorbers,andLowerControlArm.Thelowercontrolarmisawishboneshapedmetalstrutthatattachesthewheeltothevehicle\'sframe.Differentoptimizationtechniquesundervariousloadconditionshavebeenwidelyusedinautomobilesectorforlihtweightandfunctioningenhancement.ThisstudydealswithFiniteElementAnalysisofthe Lower control armof Mac-pherson suspension system andits optimization understaticloading condition.Theexisting design of lower control arm from one of the light commercial vehicles is selected for the study. In order to determine the deformation and stress distribution in the current design, the finite element analysis is carried out. The main aim of this paper is to optimize the lower control arm of Mac-pherson suspension system under the current boundary conditions for weight reduction. The baseline model of the lower control arm is created by using solid modeling software viz. CATIA. ANSYS Workbench is used for Finite Element Analysis and OPTISTRUCT solver module is used to generate the optimized model. The present studyis used toreducetheweight and cost ofthelower control arm bykeeping the factor of safety within permissible limits. The weight reduction in one lower control arm is observed to be 17.5%. .

Introduction

The study focuses on optimizing the lower control arm (LCA) of a vehicle suspension system to reduce unsprung weight while maintaining structural safety and performance. Suspension systems play a crucial role in vehicle stability, handling, comfort, and vibration control. Independent suspension systems, especially MacPherson Strut and Double Wishbone types, are widely used due to advantages such as lower weight, improved handling, and better ride quality. However, excessive unsprung mass negatively affects vehicle performance, fuel efficiency, emissions, and passenger comfort.

Previous studies have applied Finite Element Analysis (FEA) and topology optimization to improve suspension components by reducing weight and maintaining strength. This research aims to optimize the lower control arm by reducing its weight by 15–20%, performing structural analysis using ANSYS Workbench, applying topology optimization using OPTISTRUCT, and validating results through experimental testing.

The existing lower control arm made from AISI 1040 steel was analyzed under static loading conditions. The baseline model had a mass of 1.2 kg, maximum deformation of 8.32 mm, equivalent stress of 512 MPa, and a factor of safety of 1.21. The applied wheel load was calculated as approximately 765 N.

Topology optimization was performed by defining weight reduction as the objective while maintaining stress limits below the material strength. The optimized design removed unnecessary material while preserving structural integrity. The optimized LCA achieved a mass reduction from 1.2 kg to 0.99 kg, resulting in a 17.5% weight reduction.

FEA results of the optimized model showed:

• Maximum deformation: 11.14 mm
• Maximum von-Mises stress: 555 MPa
• Factor of safety: 1.11

Although stress and deformation increased slightly due to reduced material, the optimized design remained within safe limits.

Experimental validation was conducted using a Universal Testing Machine (UTM). The measured deflection values were:

• Baseline model: 7.7 mm
• Optimized model: 10.4 mm

The experimental results closely matched FEA predictions, confirming the reliability of the optimization approach.

The optimized design reduced vehicle suspension weight, improved efficiency, and provided economic benefits. For two lower control arms, approximately 420 g weight reduction was achieved. Material cost analysis showed savings of about ?10.84 per component, resulting in significant savings during mass production.

Conclusion

AsdeflectionandstressofmodifiedLCAiswithintherange.Thus,themodifieddesignissafe.Weightofthefinal optimizedmodelis0.99kg.Thetotalreductioninmassisobserved17.5%bykeepingFactorofsafetyforoptimized design within permissible limits. Thus the objective of weight reduction of un sprung mass and cost reduction has been achieved.

Copyright

Copyright © 2026 Mr. Kendre V. S., Mr. P. G. Sarasambi, Prof. S. P. Godase, Dr. S. D. Shinde. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.