front suspension upright for formula student e-race car
TRANSCRIPT
Front suspension upright for Formula Student race car 2015
Prepared by: Sarunas Dirse K1224148 BSc Motorsport EngineeringSupervised by: Prof. M. Necip Sahinkaya
FACULTY OF SCIENCE, ENGINEERING AND COMPUTINGSCHOOL OF MECHANICAL AND AUTOMITIVE ENGINEERING
KINGSTON UNIVERSITY LONDON
Content • Introduction•Aims and objectives• Research • Experiment and results•Discussion•Applications• Conclusion and further scope
KINGSTON UNIVERSITY LONDON
What is Formula Student?• KU e-racing Formula Student is building
e-racing car every year and competing at Silverstone.
• Formula Student e-racing car suspension team is responsible for research, design and manufacture of suspension components for the particular car.
• Front upright – a complex component of front suspension is also known as a wheel knuckle.
Aims and objectives ApplicationsDiscussionExperiment
and resultsResearch ConclusionIntroduction
KINGSTON UNIVERSITY LONDON
Aims and objectivesProblem – lack of custom made uprights in the market.
Aims of the project are to design and build a unique front suspension upright which complies with Formula student competition regulations and is specifically built for the KU e-racing car.
Objectives:
• To design front suspension geometry (caster, camber, toe and steering axis inclination).
• To create an upright which complies with geometry and can withstand forces.
• To conduct FEA analysis in order to improve the design.
• To manufacture the component and assemble the suspension.
Aims and objectives ApplicationsDiscussionExperiment
and resultsResearch ConclusionIntroduction
KINGSTON UNIVERSITY LONDON
Aims and objectives ApplicationsDiscussionExperiment
and resultsResearch ConclusionIntroduction
Upright designResearch of forces
Suspension research
Choice of FEA Software
Material research
Formula Student
regulations
Suspension research
Design of suspension geometry
Size and shape of upright
CAD model of the upright
KINGSTON UNIVERSITY LONDON
FEA AnalysisWorst case scenario:
• 1.7 G’s under braking and 0.9 G’s of lateral force at the same time.
• Maximum estimated weight of the car with a driver is 400kg
This will produce:
• Lateral force 1147.77 N
• Longitudinal force 2501.55 N
• Caliper torque 251.34 Nm
Material used for simulation:
Aluminum 7075 T-6
Aims and objectives ApplicationsDiscussionExperiment
and results (1)Research ConclusionIntroduction
KINGSTON UNIVERSITY LONDON
Al 7075 T-6 ResultsAims and objectives ApplicationsDiscussionExperiment
and results (2)Research ConclusionIntroduction
Stress Strain Displacement
KINGSTON UNIVERSITY LONDON
Al 6063-T6
Al 7075-T5
Ti-Al CP G4
0 100 200 300 400 500 600Max. Stress
Max. Stress
Max. Stress
Yield Strength
Yield Strength
Yield Strength
Maximum Stress and Yield Strength (Mpa)
AL 6063-T6
AL 7075-T5
TI-AL CP G4
0 0.02 0.04 0.06 0.08 0.1 0.12 0.14 0.16 0.18 0.20.18
0.18
0.12
Maximum Displacement (mm)
Aims and objectives ApplicationsDiscussionExperiment
and resultsResearch ConclusionIntroduction
AL 6063-T6
AL 7075-T5
TI-AL CP G4
0 0.5 1 1.5 2 2.50.93
2.17
2.2
Factor of safety
KINGSTON UNIVERSITY LONDON
The position in the assembly
The successful design of front upright will be used in Formula Student 2015 race.
The design of front suspension upright can be used as a template to manufacture the rear suspension upright.
Aims and objectives ApplicationsDiscussionExperiment
and resultsResearch ConclusionIntroduction
Cone roller bearings
Brake caliper Wheel hub
KINGSTON UNIVERSITY LONDON
Conclusion and further scope After conducting research and carrying out numerous experiments the unique front suspension upright has been designed.
It complies with the regulations of Formula Student competition and will be 3D printed and used in the race at Silverstone by KU e-racing team.
CAD model can be improved to achieve stiffer component structure. Tremendous knowledge is gained in suspension components and FEA analysis.
Aims and objectives ApplicationsDiscussionExperiment
and resultsResearch ConclusionIntroduction
KINGSTON UNIVERSITY LONDON
Thank you for your attention!