2012 formula sae outboard suspension
DESCRIPTION
2012 Formula SAE Outboard Suspension . Jose Colin Efe Yildirim Chip Larson Rick Rickert Carole Gayley Thomas McCall Industry Advisor: Evan Waymire Academic Advisor: Lemmy Meekisho. Overview. Introduction/Background Mission Statement Final PDS Summary External Search - PowerPoint PPT PresentationTRANSCRIPT
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2012 Formula SAE Outboard Suspension
Jose ColinEfe YildirimChip LarsonRick Rickert
Carole GayleyThomas McCall
Industry Advisor: Evan WaymireAcademic Advisor: Lemmy
Meekisho
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Overview•Introduction/Background •Mission Statement•Final PDS Summary•External Search•Internal Search•Concept Selection•Deadlines
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BackgroundEach year, Viking Motorsport (VMS) designs
and builds an open wheel racecar.
• Max 610cc displacement engine• Min 8” diameter wheels• Min 60” wheelbase• No minimum weight
2012 Competition: June 20-23 in Lincoln, NE
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Mission Statement
Redesign hubs and uprights for:• VMS designed centerlock wheel• Decreased weight• Reduced machine time and cost
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Final Product Design Specification Summary
Priority Requirements Primary Customer Goal Metric Target Target Basis Verification
5 2011 & 2012 parts
interchangeable
FSAE Team Back-up system in case
of failure
N/A N/A Customer
defined
Prototype
5 Centerlock nut
retention with two
threads exposed
(FSAE rule)
Driver Keep the wheel on the
car
On/Off On Driver’s
Safety
Nut cannot be
removed in
one step
4 Hub Weight FSAE Team Decrease weight Pounds 2lb Customer
defined
Prototype
4 Ease manufacturing FSAE Team/
Manufacturing
Decrease complexity Machining
time (min)
80 minutes Customer
defined
Prototype
3 Hub Cost FSAE Team Lower Cost Dollars ($) $200 Hub Customer
defined
Machine Shop
invoice
2 Service Life FSAE Team/
Driver
Ensure sufficient
reliability
Operating
life (years)
2 year life Customer/
group
FEA/Prototype
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External Search
Hub/upright clamped by axle, separate wheel nutBrake rotor and wheel driven by pins
Swift 016 rear outboard suspension
Existing Race Designs
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External Search
Taylor Race FSAE/DSR hub and upright assembly
Off the Shelf Option
• Centerlock or multi lug hub• Oversized for FSAE
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External Search
Force India splined wheel/hub
Wheel/Hub Engagement
Splines Drive Pins
• Excellent engagement• Expensive/difficult to manufacture
• Cheap/easy to manufacture• Clearance between wheel and pins
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External SearchTripod CV Joint
Integrated (2011 style) External• Less weight• Retain 2011 axle length• Higher machine time
• Available off the shelf• Potentially higher weight
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External SearchWheel Nut Retention – Important!
• FSAE Rule
• Porsche recall
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Internal SearchWheel Nut
Large (~ 2”) Tapered Aluminum
• Centers wheel
• Expensive• Lower clamp force
Small (1/2” – 1”) Steel Hex
• Inexpensive• Higher clamp force
• Requires wheel centering method
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Internal SearchWheel Nut Retention
Spindle Nut Retainer
• Inexpensive• Readily available • 15* pin resolution
• Difficult to produce custom units
Castle Nut
• Available in many sizes• Able to modify existing nut
• Cuts reduce thread engagement• Poor pin resolution (60*)
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Internal SearchBrake Hat
2011 brake hats were integrated into hub
• Excess machine time• Required larger OD material
2011 Integrated Brake Hat Separate Brake Hat
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Internal SearchWheel Speed Sensor
2011 Wheel speed sensors taped to the uprights
Custom tone rings were machined, threaded onto hubs
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Internal SearchUpright
Small changes:
• Retain 2011 geometry• Reduce machine time• Increase rigidity
• Relocate wheel speed sensor
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Concept Selection
Hub – Hardened Steel
Integrated CV joint• Lighter• Retain 2011 axle
Front and rear hubs identical• Reduce design/FEA time• Remove CV from front
Upright – Aluminum
• High strength• DuctileMost likely 6061-T6
Wheel Speed Sensor• Threaded into upright• Read slots in brake disc
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Concept SelectionSeparate Brake Hat
• Cut from plate• Manufactured in-house• Material choice• Allows smaller OD stock for hub
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Concept SelectionSteel Wheel Nut
• No more than 300lbf.ft installation torque• Clamp force must prevent slip on brake/acceleration
Must be < 1.1” nominal diameter
Spindle Nut Retainer• Readily available for metric hex nuts• 5* resolution with 3 pin holes
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Concept SelectionDrive Pins
Safety net in case of loose wheel nut
• Dowel Pins pressed into hub• Engage brake hat and wheel
• Allows driver to safely park the vehicle
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Design Progress
• 2G cornering, acceleration, braking• Infinite life• Target FOS = 1.5• Weight = 1.55lbf rear (2011 = 3.1lbf)
= 1.40lbf front
• M16x2.0 Wheel Nut• 175lbf.ft torque
• 3” round stock (2011 required 5”)• Machining donated by ARE Mfg.• Heat treating donated by Beaver Heat Treat
Hub and Wheel Nut
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Design Progress
• Wheel centered by 1.3” OD aluminum pilot• (3) ¼” OD x 1” long steel dowel pins• 30* cone angle wheel nut spacer distributes clamp load
Peripheral Components
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Project ScheduleMarch
• Validate hub design with FEA• Produce 2 sets of hubs
• Design wheel pilot and spacer• Design uprights
April• Validate upright design with FEA• Produce 2 sets of uprights• Choose wheel bearings• Design brake hats
May• Produce brake hats, pilots, and wheel nut spacers
• Assemble outboard suspension• Conduct on-vehicle testing
June• Final report
• FSAE competition
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QuestIons?