In my first year as a suspension & chassis subteam member of Olin Electric Motorsports, I designed, analyzed, and assembled the rear uprights of the vehicle. The upright of the vehicle is the interface between the wheel and the suspension members; It serves as the primary method of load transfer from the tires to suspension members. The forces generated at the contact patch are translated through the bearings and bore of the upright. Therefore, analysis in ANSYS included a max acceleration case (rear weight transfer), max acceleration + max turning case, and max braking force case.
The geometry of the component focused on the manufacturing capabilities of our college's shop and access for tooling during the assembly and tuning process. The 3D surfacing of the part was designed to be made with a single pair of soft jaws to alleviate unnecessary setup changes.