front suspension upright for formula student e-race car

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


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


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.






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


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


and results (1)Research ConclusionIntroduction


Al 7075 T-6 ResultsAims and objectives ApplicationsDiscussionExperiment

and results (2)Research ConclusionIntroduction

Stress Strain Displacement


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)



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


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.



Cone roller bearings

Brake caliper Wheel hub


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.




Thank you for your attention!

front suspension upright for formula student e-race car

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