Design and Manufacturing of Suspension and Steering System of a F3 Vehicle

Year : 2025 | Volume : 15 | Issue : 03 | Page : 1 12
    By

    Shobhit Tyagi,

  • Yuvraj Manrai,

  • Ayush Midha,

  • Parth Pruthi,

  • Rakesh Chander Saini,

  1. Student, Department of Mechanical Engineering, Maharaja Agrasen Institute of Technology, New Delhi, India
  2. Student, Department of Mechanical Engineering, Maharaja Agrasen Institute of Technology, New Delhi, India
  3. Student, Department of Mechanical Engineering, Maharaja Agrasen Institute of Technology, New Delhi, India
  4. Student, Department of Mechanical Engineering, Maharaja Agrasen Institute of Technology, New Delhi, India
  5. Assistant Professor, Department of Mechanical Engineering, Maharaja Agrasen Institute of Technology, New Delhi, India

Abstract

The suspension and steering systems are critical subsystems of any formula-style racing vehicle, directly influencing its stability, handling, and driver safety. This paper focuses on the design, analysis, and manufacturing of suspension and steering systems for a Formula Student F3 vehicle. The primary objective is to develop a lightweight, reliable, and efficient design that complies with Formula Student competition rulebooks while ensuring optimum ride quality and performance. Using advanced computer-aided design (CAD) tools such as SolidWorks and engineering simulation software including Lotus and ANSYS, the suspension and steering geometries were developed and validated through numerical analysis. The suspension system was designed with a double-wishbone geometry combined with push-rod and pull-rod actuation mechanisms, which provide superior motion ratios, improved aerodynamics, and better cornering stability. Key design parameters such as scrub radius, caster angle, camber variation, suspension travel, and roll center height were optimized to minimize bump steer, improve handling, and maintain tire-road contact during dynamic events. The ratio of wheelbase to trackwidth was found to provide a balance between high-speed stability and maneuverability. AISI 1018 steel was selected for the spaceframe chassis due to its high strength-to-weight ratio, excellent weldability, and durability under high torsional and impact loads. The steering system was developed using Ackerman geometry to ensure precise cornering performance. Calculations for steering angles, rack-and-pinion geometry, tie-rod lengths, and turning radius were performed to achieve an Ackerman percentage close to the ideal value, thereby reducing tire slip and enhancing driver control. Simulation and analysis confirmed that the chosen suspension and steering configurations provided adequate stiffness, durability, and safety margins under braking, cornering, and impact conditions. The results of this work demonstrate that the integrated suspension and steering system not only meets competition safety and design guidelines but also enhances performance through improved handling, reduced weight, and driver comfort. This design methodology can serve as a reference framework for future Formula Student teams aiming to optimize their vehicle’s performance.

Keywords: Suspension, Steering, Chassis, Scrub, Castor, Ackerman, Toe

[This article belongs to Trends in Mechanical Engineering & Technology ]

How to cite this article:
Shobhit Tyagi, Yuvraj Manrai, Ayush Midha, Parth Pruthi, Rakesh Chander Saini. Design and Manufacturing of Suspension and Steering System of a F3 Vehicle. Trends in Mechanical Engineering & Technology. 2025; 15(03):1-12.
How to cite this URL:
Shobhit Tyagi, Yuvraj Manrai, Ayush Midha, Parth Pruthi, Rakesh Chander Saini. Design and Manufacturing of Suspension and Steering System of a F3 Vehicle. Trends in Mechanical Engineering & Technology. 2025; 15(03):1-12. Available from: https://journals.stmjournals.com/tmet/article=2025/view=227944


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Regular Issue Subscription Original Research
Volume 15
Issue 03
Received 07/08/2025
Accepted 30/08/2025
Published 15/09/2025
Publication Time 39 Days
330

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