1. Front Unsprung
Mass
DESIGN PROJECT

2. Objective
 Redesign the front unsprung assembly
 Reduce the weight
 Maintain strength

3. Design Brief
 Redesign
 Brake Disc
 Hub
 Upright
 Reduce mass by 30%
 Select bearing
 Bearing at camper angle

4. Calculations

5. Upright
From this To this

6. FEA Analysis
 Weight = 825 g
 Factor of safety= 7

7. FEA Analysis
 Redesigned
 Weight = 735 g
 Factor of safety= 9.77

8. Sustainability (Upright)
Die Casted Milled

9. Sustainability (Brake Disc)
Cast Iron Carbon Steel

10. 3D Model
Hub
• Weight – 246 g (700g)
• Material – 7075 T6

11. 3D Model
Brake Disc
• Material – Gray Cast Iron
• Weight – 590g (1597g)

12. 3D Model
Upright
• Material – 7075 T6
• Weight – 735g (1393g)

13. 3D Model

14. 3D Model

15. Exploded View

16. Conclusion
 Objectives achieved
 Weight reduced
 Maintained strength
 Appropriate bearing was picked
 Redesigned overall assembly

17. Thank You
Questions ??