Wishbone Control Arm Additive Manufacturing and Swaged Bushing
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Solution Overview
Problem
Conventional wishbone-style control arm manufacturing involves significant material waste and complexity due to machining operations, resulting in heavy and unwieldy components that adversely affect vehicle performance and fuel efficiency.
Innovation Solution
A three-piece wishbone-style control arm assembly is created using additively manufactured segments with aligned connecting features and a press-fit swaged bushing, eliminating the need for mechanical fasteners and adhesives, thereby reducing mass and complexity while maintaining structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional machining operations are used to manufacture wishbone-style control arms, then structural integrity can be achieved, but significant material waste occurs and the components become heavy and complex
Solution Approach 1:
The control arm is divided into multiple segments that are manufactured separately using additive manufacturing and then connected through connecting features. This segmentation allows each segment to be optimized independently, reducing overall material usage while maintaining structural integrity through the connection architecture.
Solution Approach 2:
The manufacturing method transitions from conventional machining to additive manufacturing, fundamentally changing the production parameter approach. Additive manufacturing builds components layer-by-layer, eliminating material removal and significantly reducing waste while maintaining or improving structural properties.
2Strength
If mechanical connectors and fasteners are used to connect control arm segments, then structural integrity is maintained, but the mass and complexity of the assembly increase
Solution Approach 1:
The connecting features are integrated directly into the segments themselves rather than being separate components. The bushings are press-fit and swaged into recesses that are part of the segment geometry, merging the connection function into the structural components and eliminating the need for separate mechanical fasteners.
Solution Approach 2:
Traditional mechanical connectors and fasteners are extracted from the assembly, replaced by a simpler press-fit and swage connection system. This removal of unnecessary components directly reduces mass and complexity while maintaining the required structural integrity.
3Manufacturing precision
If conventional machining operations are used, then manufacturing precision can be achieved, but device complexity and manufacturing complexity increase
Solution Approach 1:
The manufacturing process parameter changes from subtractive machining to additive manufacturing. This fundamental change simplifies the manufacturing workflow by building components directly from digital models, eliminating complex machining setups, tool paths, and material removal operations while maintaining dimensional accuracy through controlled layer deposition.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution results in a lightweight, streamlined control arm that minimizes material waste, reduces mass, and enhances vehicle performance by providing efficient axial load paths while minimizing out-of-plane loads, thus improving fuel efficiency and structural integrity.
Implementation Method 1
press-fitting a bushing into the aperture
Implementation Method 2
swaging the press-fitted bushing
Data Source
AI summary
Wishbone-style control arm assemblies for a vehicle and methods for assembling the same are disclosed. A control arm assembly includes a first elongated segment having a first connection feature at one end of the first segment. The control arm assembly includes a second elongated segment having a second connection feature at one end of the second segment. Opposite longitudinal ends of the first and second segments may include third and fourth connection features, respectively, that are configured to interface with the vehicle. The first and second connection features are aligned to form an aperture that extends at least partially through the first and segment connection features, through which a bushing is press-fit and then swaged to form a strong connection that reduces or eliminates the need for mechanical fasteners or adhesive bonds. The bushing connection independently enables the control arm to maintain a secure connection between segments during operation of the control arm when assembled in the vehicle.