Suspension Control Arm (Wishbone)

Create a 3D CAD model of an automotive suspension control arm (wishbone / A-arm) for a college-level finite element stress analysis project. 1. Overall geometry - Create a triangular, wishbone-shaped suspension control arm consisting of two load-bearing arms connected to form a V-shape. - At the two ends of the wider side, create two cylindrical chassis mounting bosses. - At the narrow outer end, create one cylindrical ball-joint mounting boss. - The overall appearance should closely resemble a conventional automotive lower suspension control arm. - Keep the design symmetric where practical, with a clear triangular opening between the arms. 2. Suggested dimensions (mm) - Overall length: 300 mm. - Distance between the two chassis mounting centres: 180 mm. - Distance from the midpoint of the chassis mounting centres to the outer ball-joint centre: 240 mm. - Arm width: 30 mm. - Arm thickness: 12 mm. - Cylindrical boss outer diameter: 40 mm. - Cylindrical boss height: 25 mm. - Through-hole diameter in each mounting boss: 12 mm. - Add fillets of 5–8 mm at the arm-to-boss connections. - Use consistent dimensions and ensure all mounting holes are properly aligned. 3. Construction requirements - Model the two arms and mounting bosses as a connected, load-bearing component. - Ensure the arms intersect and join the bosses properly, without gaps or unintended overlaps. - Prefer a single watertight solid body, or a clean, connected solid suitable for static structural analysis. - Avoid unnecessary decorative details, threads, logos, and tiny features. - Keep the geometry simple enough for reliable tetrahedral meshing in ANSYS Mechanical. 4. Engineering requirements - Use millimetres as the modelling units. - Ensure sufficient material thickness around all holes. - Avoid sharp internal corners where practical. - Make the geometry suitable for applying fixed supports at the two chassis mounting locations and a force at the outer ball-joint location. - Do not include loads, supports, mesh or simulation results in the CAD file. 5. Export - Export the final model as a STEP file (.step or .stp). - If STEP export is unavailable, provide a Parasolid file (.x_t) or an editable native CAD file. - The final geometry must be suitable for import into ANSYS Workbench for static structural stress analysis using five different mesh sizes.

Parameters

Every value above is a live dimension. Open a model like this in the editor and each one becomes a slider you can drag before exporting.