CONTENTS

 Introduction
 Literature Review
 Problem Definition And Objectives
 Methodology
 Case Study
 Material Selection
 Future work
 Conclusion
 References

JSPMs RSCOE Mechanical Department

Introduction
 In a Formula Student Car or in any car as such, the part that
connects the main frame of the body with the wheels
through suspension arms is known as the Wheel Assembly.
 The components of the wheel assembly are knuckle, hub,
bearings, cotter pins etc.
 A lot of forces are acting on the wheel assembly during
accelerating, braking, cornering and tilting. The vehicle
must be able to sustain all the loads that are generally both
static and dynamic.

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 Literature Review
Paper
Paper Name Author Year Conclusion
No
For a component
undergoi0ng fatigue
loading, the design criteria
Designing and must always be Fatigue or
1 Optimization of Wheel Joijode Vrushabh Umesh 2016 Endurance Strength.
Assembly of a Formula and Yadav Abhishek material should be
removed from the low
Student Car stress concentration areas.

The purpose of this thesis

Manufacturing of Front Kunal Vispute1, Krushanu
Wheel Assembly of Nakade, Abhiraj Uttarwar,
2 Formula Student Rahul Deshmukh,
2017
Race Car Surendrasingh Sonaye
project is not only to
design and manufacture
the upright and hub
assemblies
but also to provide an in
depth study in the
process.

We have implemented the

shape optimization
Design Analysis & technique to optimize the
Pruthviraj Vitthal Wable1
3 Optimization of Hub Used
Sahil Sanjog Shah
2017 design of the hub which is
to be used in the
in FSAE Cars front wheel set assembly
of the car.

JSPMs RSCOE Mechanical Department

Problem Definition
• The main problem is to design the assembly having less
weight to increase the performance. As the wheel
assembly is the most critical part of the vehicle. These not
only transmit power from engine to the wheels but also are
responsible for proper steering characteristics. It has to be
done considering the available manufacturing resources.
It is difficult to design assembly that can sustain both the
static and dynamic loads.

JSPMs RSCOE Mechanical Department

Objectives
• Light weight to maintain good performance to
weight ratio of race car.
• Optimum stiffness to ensure reliability of upright
assembly and to maintain designed geometry of
suspension system.
• Ease of maintenance for enhancing serviceability
and setup repeatability.
• To design and fabricate upright assembly
component in house to reduce turnaround time and
outside dependability.

JSPMs RSCOE Mechanical Department

Methodology
1. Material Selection And Getting the prerequisite parameters:-
Parameters such as King Pin Angle, Steering Arm angle, Tie rod angle
are obtained from the Steering geometry, whereas the Caster angle, the
angle of upper A-arm and the lower A-arm, Rear Track width are
obtained from Suspension Geometry.
2. Force Calculations:-
The forces acting on the knuckle are:-
1) Weight of the vehicle
2) Longitudinal Forces during Braking
3) Lateral Forces
The following Forces are acting on the Hub are
1) Torque on the Brake Disk Petal
2) Loads on Bearing
3) Bump force on the tire

JSPMs RSCOE Mechanical Department

Methodology
3. Part Modeling and FEA
With its easy to use interface and high functionality during assembly, SolidWorks
and Catia are the best software packages available for part modeling of the hubs and
uprights. These softwares are used to make a 3D part.
The FEA package allows for the computation of stresses in different ways.

4. Optimization
The FEA results are compared against the fatigue strength of the material
corrected for a known service life. The correction factors followed that of a standard fatigue
calculation and takes into account of load factor, size factor, surface quality, operating
temperature, and reliability.
There are three types of optimization options available in FEA packages
1) Shape optimization
2) Size optimization
3) Topology optimization

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Case Study

Fig. exploded view of

Wheel Assembly

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Case Study

Fig. Analysis of Knuckle Fig. Analysis of hub

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Material Selection
Future work
• For the future work, it is necessary to reduce the
unsprung mass that is hub, upright, bearing. For that
selection of the light weight and high strength
material is to be done and find alternative materials

JSPMs RSCOE Mechanical Department

Conclusion
1) It has been demonstrated through a range of experimental results
that lighter weight of upright assembly and the required stiffness is
achieved by optimum design calculations and less complex design.

2) For carrying out optimization, material should be removed from the

low stress concentration areas.

3) We found that weight can be reduced using structural optimization

process. After applying load and design constraints, stress analysis and
shape optimization performed, weight reduction can be observed.

JSPMs RSCOE Mechanical Department

References
1) Jijode Vrushabh Umesh and Yadav Abhishek, “Designing and Optimization of Wheel
Assembly of a Formula Student Car”, International Journal of Current Engineering and
Technology E-ISSN 2277 – 4106, P-ISSN 2347 – 5161 Mechanical Engineering Department,
Vishwakarma Institute of Technology, 666, Upper Indira Nagar, Pune-37, India.

2) Kunal Vispute, Krushanu Nakade, Abhiraj Uttarwar, Rahul Deshmuka and Surendrasingh
Sonaye, “Design, Analysis and Manufacturing of Front Wheel Assembly of Formula
Student”, International Conference on Ideas, Impact and Innovation in Mechanical
Engineering (ICIIIME 2017) ISSN: 2321-816 Volume: 5 Issue: 6.

3) Pruthviraj Vitthal Wable and Sahil Sanjog Shah, “Design Analysis & Optimization of Hub
Used in FSAE Cars”, International Journal of Innovative Research in Science, Engineering
and Technology Vol. 6, Issue 8, August 2017.

4) Mr.Sangram K. Pisat, Mr.Aditya S. Phule, Mr.Rohan R. Shinde and Prof. Arun V. Javir,
“Design and Analysis of Hub and Knuckle of FSAE Race Car”, IJSRD - International Journal
for Scientific Research & Development| Vol. 4, Issue 02, 2016.

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Thank You