Aston Martin - Front Suspension Arm



The Aston Martin Vanquish went into production in 2001 with a 6 litre V12 engine producing 460bhp with a top speed of 190mph. Safety critical components have to be able to withstand the demands of this high performance car.

HPC was tasked with reverse engineering the Aston Martin Vanquish suspension arms. Initially the component was scanned on an HPC Zeiss co-ordinate measuring machine. From this data it was possible to create a Solid Edge electronic model and then change design features prior to producing a new forging.

 From the electronic solid model, HPC engineers then designed work-holding fixtures around the machined features. The model was then used to create the machine tool CNC program. The next stage of development was to electronically proof machine the component, animating the tool length, spindle and work holding. This simulation of the machining process proved out all 17 tools and led to a number of machining advancements including high speed machining in place of traditional form tools.

To complete the development process the newly machined components were dimensionally verified against the electronic solid model and a process of sample inspection continues throughout the current production process.

HPC has the experience of a variety of assembly processes. The Aston Martin project required a new assembly area to be constructed to insert and test three void bushes into the suspension arms; a twin head hydraulic press is then employed to complete this task. Mounted on a bespoke vice, the design requires that the larger bush be fitted in a controlled radial position, critical to the geometry of the Vanquish suspension design.

The Vanquish suspension arm is typical of HPC's ability to project manage an engineered solution and is one of several long-term partnerships between HPC and Aston Martin.