Lightweight Design of a Multi-Material Suspension Lower Control Arm

This paper is focused on the design, analysis and testing of a multi-material (carbon fibre and steel) Lower Control Arm (LCA) of a McPherson suspension for a C segment vehicle. Therefore, starting from the existing component (made of steel), the LCA mass has been reduced by using a hybrid technology, diminishing the steel thickness and adding a carbon fiber tailored cover without compromising the mechanical performance in terms of stiffness and stress distribution. In so doing, it has been possible to evaluate the potential and the capabilities of the hybridization without re-designing the component totally. In particular, it has been developed a specific methodology that combines both virtual and experimental procedures to face the hybridization challenges of mechanical coupling, safety and lightweight. For these reasons, the multi-material lower control arm represents a noticeable case study in which this methodology has been applied, correlated and validated.