INSTRUCTION MANUAL

DEMOSTRATION MODEL OF FRONT WHEEL

ASSEMBLY

Manufactured By

Xtreme Engineering Equipment (P) Ltd.

Factory/Off.: Xtreme House, S.N 32/2, Ashtavinayak Indl.
Estate, Parvati Nagar, Next to Pari Robotics, Narhe, Pune –
41,
Tel.020-24690312,
INDEX

SR.NO
DESCRIPTION PAGE NO.
.

1 System Components 03
2 Photograph of System 04
3 Introduction 05
4 System Description 08
5 Working and Construction 10

1.

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 1. SETUP COMPONENTS

After unpacking the consignment, you will find the following items mounted on the
main structure.

 Stand
 Disc brake
 Caliper
 Suspension strut with spring
 Shock absorber
 C.V Shaft or Drive Shaft

Kindly remove all the packing material & clean the components if required. Please
check the components as per list. If you have any difficulty, please feel free to
contact us.

2. PHOTOGRAPH OF SYSTEM

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 3. INTRODUCTION
 Front Wheel Assembly:
The wheel assembly is an integral part of a Formula SAE (FSAE) car and
consists of several components such as the upright, braking system, hub shaft and
wheel. Each component must be designed to account for factors that will affect the
entire assembly and its function.
The upright is a major component to the wheel assembly as its function is to
provide a connection between the suspension and wheel, plus a mounting point for
the brake caliper. It is constantly in motion with the wheel and is a load-bearing part
of the suspension system. The brake system is an important part of the wheel
assembly and consists of the caliper and disc. Both must be designed to work
cohesively with each other, specifically to prevent brake fading.

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 The brake caliper is the most important component of the braking system as
it contains one or more pistons and brake pads. Hydraulic pressure will build up in
the piston/s and force the pads against the brake disc, consequently stopping the car.
In FSAE racing, the car will travel at high speeds and braking will generate
excessive heat quickly. Therefore, it is essential that the brake calipers are
lightweight and properly ventilated. Brake calipers must be chosen before the size of
the disc, upright and shaft can be evaluated. This decision is based on the size of the
wheel and mass of the car.

 Suspension:
The main job of a car suspension system is to ensure that there is maximum
friction between the tyres and the surface of the road, to provide steering stability
with good handling, and to ensure the comfort of the passengers. It is intent to
absorb vibration, gravitation, and impact forces from the road. If every road were
completely flat, with no bumps, potholes, or irregularities, suspension systems
would not be necessary. But this is not the case anywhere in the world. Even freshly
paved streets have tiny imperfections that can interfere with the wheels of a car and
how it is running. These imperfections apply force to the car, pushing it upwards.

The magnitude of the force, of course, depends on how large the open that has been
hit is. Either way, the car wheel experiences a vertical acceleration as it passes over
an imperfection. It’s the job of the suspension system to deal with these upwards
forces and ensure that the wheels stay on the road at all times. If it does its job right
and the wheels are constantly in contact with the surface of the road, then there is
maximum friction and the risk of rolling or flipping the car over is minimized and it
helps to make sure that power is transmitted to the wheels, where it is needed the
most.

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The tyres absorb all the shocks and vibrations, as well as other imperfections in the
road, and in conjunction with the car’s shock absorber mechanism as part of the
suspension, the effects of these shock forces can be effectively dampened. It is
technically the spring mechanism of modern suspension systems that pushes the
tyres into the ground so that we have maximum friction and the best ride possible.
So when a tyre hits a bump or is forced upwards because of something in the road,
it’s the suspension system that pushes the tyres back onto the ground and keeps the
car as stable, safe, and comfortable as possible.

4. SYSTEM DESCRIPTION
1. Stand:
This is made up of MS square tubes and sheets. Especially powder coated for
Durability. All components are mounted on base stand.

2. Disc Brake :
The function of disc brakes in a car is to control the vehicle's speed so that it can
run and stop according to the wishes of the driver. Disc brakes will make the
driver safer in controlling the car.

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 Brake fluids are the means through which pressure is transfer to the wheel
cylinders. Hydraulic brake fluids must have a low freezing point, water tolerance,
lubrication, non-corrosiveness, proper viscosity, and high boiling point.

3. Brake Caliper:
The job of the caliper is to slow the Vehicle wheels by creating friction with the
rotors. The brake caliper fits over the rotor like a clamp. Inside each caliper is a
pair of metal plates bonded with friction material these are called brake pads.

4. Suspension strut:
struts provide structural support for the vehicle’s suspension. As a result, struts
affect riding comfort and handling, as well as vehicle control, braking, steering,
wheel alignment and wear on other suspension components, including the tyres.

5. Shock Absorber:
The strut will usually carry both the coil spring, on which the body is suspended,
and the shock absorber, which is usually in the form of a cartridge mounted within
the strut. The strut can also have the steering arm built into the lower outer
portion.
6. C.V Shaft or Drive Shaft:
The CV axle shaft is an important component of front-wheel drive vehicles. It
links the driveshaft and the transmission, allowing the wheels to turn. It transfers
torque so that the wheels will turn at a constant speed.

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 5. WORKING AND CONSTRUCTION
 Front wheel suspension system:
A suspension works on the principle of force dissipation which involves
converting force into heat thus removing the impact that force would have made. It
uses springs, dampers and struts to achieve this. A spring will hold the energy
while a damper will convert it into heat. Below we have shown how they perform
this step.
Suspension is the definition given to the system of springs, shock absorbers
and linkages that joints a vehicle to its wheels and allows relative motion between
the two. Suspension systems allow dual purpose contributing to the vehicle's road
holding/handling and braking for good active safety and driving pleasure, and
keeping vehicle occupants comfortable and reasonably well isolated from road noise,
bumps, and vibrations, etc.

MacPherson suspension system is generally used as the front suspension

system in the passenger cars. Where MacPherson suspension system uses less space
and provides more area to engine compartment.
MacPherson suspension system to give more comfortable and modification on
suspension system is done. A MacPherson strut uses a wishbone, or a substantial
compression link stabilized by a secondary link, which provides a mounting point
for the hub carrier or axle of the wheel. The lower arm system provides both lateral
and longitudinal location of the wheel.
The MacPherson strut takes over the tasks of a steering rod and serves
simultaneously for suspension and vibration damping. The advantages of this system
are, firstly, the space and weight-saving construction, and secondly, the large spring
travel.

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9 DEMOSTRATION MODEL OF FRONT WHEEL ASSEMBLY
Xtreme Engineering Equipment (P) Ltd.