Design of Alternative Front Axle Disconnect Actuator (FADA) Housing Joints

In use on over eight million 4×4 vehicles on the road today, the front axle disconnect actuator (FADA) is a key automotive component that disconnects the front axle from the drivetrain to improve fuel economy. The current joint design involves riveting the three plastic housings together with two sets of three rivets which is highly sensitive to dimensional variation and subsequent failure. Stoneridge has requested our team to redesign new joining methods for the external housings of FADA focusing on key requirements such as durability, cost, overall dimensions, and ease of manufacturability.

Course: ME 450

Instructional Team: Prof. Randy Schwemmin

Project Member(s): Jared Shattuck

Project Sponsor: Stoneridge