Formula SAE Suspension

Project Proposal

EML 4501C/ EAS 4700C Senior Design Group: #11

Team Redline
Chevy Butman Gregory Benjamin Manny Garcia Nicholas Schiavone Phillip Blitz Dr. Lionel Hewavitharana Lionel.Hewavitharana@ucf.edu Phone: 407-823-1013 EGN1-217 2/14/2012

Objective

Formula SAE is an international, collegiate, engineering competition that challenges teams of students to conceive, design, fabricate, develop and compete with small, open-wheel formula car. We will be developing the suspension system for the upcoming car. This requires many aspects of engineering, including kinematics, vibrations, and machine design. Some of the Objectives include: Compete against other Universities from around the world and place well To better understand how the car reacts in dynamic conditions Maximizing performance of tires through tire data and kinematics (maximum lateral force into the tires) Minimizing unsprung mass for a faster reacting suspension Determining ride and roll rates of the suspension to better control weight transfer and vibrations Design and fabricate components of the suspension

Project Justification The Formula SAE competition is a student design competition with a large following by universities worldwide. The suspension design and longevity for these vehicles is crucial to their performance. Given that the rules are fairly unrestricted, the team responsible for designing the suspension components can play a major role in the cars overall performance. With over a hundred teams competing annually, many different suspension concepts and designs are on showcase for the world to see. While the obvious objective for this project is to score points competitively, suspension design is constantly being optimized by major race teams and mainstream manufacturers alike. Techniques used in the design and manufacture of suspension for a SAE car can be applied to multiple fields of the automotive industry. Almost any suspension design is accompanied by a series of compromises. For example, a stronger and less compliant suspension design may be significantly heavier. Obviously reducing

weight is a major factor in racing, which leads to a compromise. This sort of optimization warrants a team of engineers to work to find the best compromise. Herein lies the challenge presented to the team and the justification for the project. The idea is to engineer a system to reduce the compromises. Whether it be to use a new and innovative idea or to optimize a preexisting system, a team of knowledgeable engineers is required to effectively design and manufacture an effective suspension system. This knowledge and skillset will provide invaluable for the team both during the competition and afterwards. The experience can be passed on to the following generations of SAE or used in larger scale racing or automotive applications.

Project Deliverables The end goal of this project will be a fully developed suspension system much like those used in past SAE competitions, designed for optimum track performance and allowing, per SAE rules, for a minimum of 2 inches of usable wheel travel, and 1 inch minimum of rebound. In addition to meeting bare minimum requirements, the suspension must perform. Since the competition involves over a hundred competing teams, a suspension that allows for superior handling and delivers reliability will be key. The suspension system is to be designed using SolidWorks for modeling. SolidWorks, along with additional software packages (yet to be determined) will be used to perform structural and kinematic analysis of the design, before it can be implemented. The designs considered are either a pushrod, pullrod or some variant of these systems, and testing will help determine which design is a better fit for the performance characteristics desired. In order to build the vehicle the required parts will have to be purchased. The parts necessary, such as the control arm (or A-arm), the dampers and springs, the uprights, the tie rods that connect to the steering input, the bell-crank and hub will be chosen based on the quality of the part as well as the cost considerations of our budget. The budget should also

reflect practical application, allowing the design to be produced or replicated without exorbitant expense. The chosen components and materials should reflect appropriate quality, longevity, and safety standards that any sanctioning body would require. The intent is to have a design chosen by the end of the semester, and to finally build the system for the 2013 car during the upcoming fall semester, for real-world testing and refinement. This semester will be focused on the design phase, the pros and cons of different ideas, and a design that is optimally suited for track conditions will be selected. The fabrication will unfold in the following semester making extensive use of the SAE garage on campus due to the teams extensive manufacturing abilities and experience. Once again, applicable safety measures will be taken to ensure components are of high quality and have a long service life. Scope of Work I. Technical Task List a. The technical task list involves initial design of the overall suspension using

OptimumK software package, design of individual suspension parts, assembly of parts and analysis of these components. Alongside the major technical tasks, each member is responsible for weekly reports, peer evaluations, monthly reports and design reviews. II. a. b. c. d. e. III. a. Key Name List Chevy Butman Team Leader Gregory Benjamin Operations Manger Phillip Blitz Tooling Engineer Emmanuel Garcia Process Engineer Nicholas Schiavone Design Engineer Task 1 Administration Preliminary meeting was conducted were team members are introduced, SAE

Garage tour was held and objectives were discussed.

b. c. d.

10 Hours per week minimum required, total 150 hours for this semester. Weekly Meeting with Dr. Hewavitharana will be held Tuesdays at 7pm. Organizational materials assigned (GroupMe, Dropbox, Facebook Group,

Contact List, Schedules, Vehicle Dynamics Literature) IV. a. Technical Task 1: Kinematics The goal of this task is to, using Optimum K software, provide points of where

major components should be connected to gain the range of motion desired and to utilize the b. The Recipient of this task shall perform analysis of the general kinematic

motion of the suspension system. The design of the suspension and linkages must first be placed. The motion will then be applied to the suspension in defined regions. The motion can consist of Roll, Pitch, Heave and Steering, and can be applied either individual of simultaneously. Once complete store all data. c. V. a. b. Products used include OptimumK software package. Technical Task 2: A-Arm Design Goal of this task is to design a lightweight, structurally compliant A Arm The Recipient of this task shall design the A Arm using the measurements of

the linkages from the OptimumK results. SolidWorks must be used for the design and analysis. The design of the A Arm must also coincide with the connection points of the adjacent parts. Some finite element analysis is required. Mechanical analysis and description of the mechanical properties is required as well. Once design is approved, manufacturing and procurement will begin. c. VI. a. Products used include OptimumK results, SolidWorks CAD software. Technical Task 3: Damper/Spring Goal of this task is to design a lightweight, structurally compliant

Damper/Spring.

b.

The Recipient of this task shall design the Damper/Spring system using

measurements of the linkages from the OptimumK results. SolidWorks must be used for the design and analysis. The design of the Damper/Spring system must coincide with the connection points of the adjacent parts. Some finite element analysis is required. Mechanical analysis and description of the mechanical properties is required as well. Once design is approved, manufacturing and procurement will begin, so be aware of necessary parts specifications. c. VII. a. part. b. The Recipient of this task shall design the Push/Pull Rod part using Products used include OptimumK results, SolidWorks CAD software. Technical Task 4: Push/Pull Rods Goal of this task is to design a lightweight, structurally compliant Push/Pull Rod

measurements of the linkages from the OptimumK results. SolidWorks must be used for the design and analysis. The design of the Damper/Spring system must coincide with the connection points of the adjacent parts. Some finite element analysis is required. Mechanical analysis and description of the mechanical properties is required as well. Once design is approved, manufacturing and procurement will begin. c. VIII. a. b. Products used include OptimumK results, SolidWorks CAD software. Technical Task 5: Bell-Crank Goal of this task is to design a lightweight, structurally compliant Bell-Crank. The Recipient of this task shall design the Bell-Crank part using

measurements of the linkages from the OptimumK results. SolidWorks must be used for the design and analysis. The design of the Bell crank must coincide with the connection points of the adjacent parts. Finite element analysis is required. Mechanical analysis and description of the mechanical properties is required as well. Once design is approved,

manufacturing and procurement will begin, so be aware of necessary parts specifications and manufacturers requirements. c. IX. a. Rod. b. The Recipient of this task shall design the Steering Tie Rod using Products used include OptimumK results, SolidWorks CAD software. Technical Task 6: Steering Tie Rods Goal of this task is to design a lightweight, structurally compliant Steering Tie

measurements of the linkages from the OptimumK results. SolidWorks must be used for the design and analysis. The design of the Tie Rods must coincide with the connection points of the adjacent parts. Finite element analysis is required. Mechanical analysis and description of the mechanical properties is required as well. Once design is approved, manufacturing and procurement will begin, so be aware of necessary parts specifications. c. X. a. b. Products used include OptimumK results, SolidWorks CAD software. Technical Task 7: Uprights Goal of this task is to design lightweight, structurally compliant Uprights. The Recipient of this task shall design the Uprights using measurements of the

linkages from the OptimumK results. SolidWorks must be used for the design and analysis. The design of the Uprights must coincide with the connection points of the adjacent parts. Finite element analysis is required. Mechanical analysis and description of the mechanical properties is required as well. Once design is approved, manufacturing and procurement will begin, so be aware of necessary parts specifications. c. XI. a. Products used include OptimumK results, SolidWorks CAD software. Technical Task 8: Hub/Spindle Goal of this task is to design a lightweight, structurally compliant Hub/Spindle.

b.

The Recipient of this task shall design the Hub/Spindle using measurements of

the linkages from the OptimumK results, and wheel and tire specifications. SolidWorks must be used for the design and analysis. The design of the Hub/Spindle part must coincide with the connection points of the adjacent parts. Some finite element analysis is required. Mechanical analysis and description of the mechanical properties is required as well. Once design is approved, manufacturing and procurement will begin, so be aware of necessary parts specifications and manufacturers requirements c. XII. a. Products used include OptimumK results, SolidWorks CAD software. Bill of Materials Prepare a Bill of Materials for the SAE Suspension Design. This document shall

include but is not limited to: i. ii. iii. A description of each item; Cost, quantity, total Company/Store Name, and link (if ordered online)