Design and Analysis of Suspension System for a Formula SAE Race Car

• Main Author: Ali, Fahmi
• Format: Final Year Project
• Language: English
• Published: Universiti teknologi petronas 2008
• Subjects: TJ Mechanical engineering and machinery
• Online Access: http://utpedia.utp.edu.my/9902/1/2008%20-%20Design%20and%20Analysis%20of%20Suspension%20System%20for%20a%20Formula%20SAE%20Race%20Car.pdf; http://utpedia.utp.edu.my/9902/

The objective of this project is to further optimize the suspension system of a Formula SAE race car with steering system included. The suspension system is designed based on unequal length double wishbone suspension system. Several changes had beenmade for the new car with the usage of hybrid composite-spaced frame chassis and single cylinder engine. Thus, new design concepts has been introduced to suit the changes made for the vehicle which include the changes in mounting points, weight distribution, suspension kinematics plane,and steering geometry. The scope of study consists of modeling the suspension and steering components by using computeraided softwaresuch as CATIA. In addition, the Finite ElementAnalysis (FEA) is performed by using CATIA which could give instantaneous yet accurate results. Dynamics analysis will compromise the usage ofADAMSCAR software which can simulate the whole suspension and steering system behavior according to the track layout which will make better understanding regarding the study. Although the fabrications of the actual product will not being carried out, the fabrication method will be inserted together in this study as reference for future planning. Based on the designing and analysis performed, the calculated roll center height and static camber angle ofthe vehicle at the static position is -68mm from the ground and - 0.5 degree respectively. In addition, the maximum lateral load transfer being transferred during cornering with radius of7.5 meters is 91.82 N. The dynamics analysis performed in ADAMSCARS shows remarkable results in open loop step steer simulation. These results provide better understanding of the vehicle performance during the autocross events.