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The suspension system of a FSAE (Formula Society of Automotive Engineers) vehicle is a vital system with many functions that include providing vertical compliance so the wheels can follow the uneven road, maintaining the wheels in the proper steer and camber attitudes to the road surface and reacting to the control forces produced by the tires (acceleration, braking and cornering). The members that comprise the suspension are subjected to a variety of dynamic loading conditions – it is imperative that they are designed properly to ensure the safety and performance of the vehicle. The goal of this research is to develop a model for predicting the reaction forces in the suspension members based on the expected load scenarios the vehicle will undergo. This model is compared to the current FSAE vehicle system and the design process is explained. The limitations of this model are explored and future methodologies and improvement techniques are discussed.
Hand-selected by racing engineer legend Carroll Smith, the 28 SAE Technical Papers in this book focus on the chassis and suspension design of pure racing cars, an area that has traditionally been - farmed out - to independent designers or firms since the early 1970s. Smith believed that any discussion of vehicle dynamics must begin with a basic understanding of the pneumatic tire, the focus of the first chapter. The racing tire connects the racing car to the track surface by only the footprints of its four tires. Through the tires, the driver receives most of the sensory information needed to maintain or regain control of the race car at high force levels. The second chapter, focusing on suspension design, is an introduction to this complex and fascinating subject. Topics covered include chassis stiffness and flexibility, suspension tuning on the cornering of a Winston Cup race car, suspension kinematics, and vehicle dynamics of road racing cars. Chapter 3 addresses the design of the racing chassis design and how aerodynamics affect the chassis, and the final chapter on materials brings out the fact that the modern racing car utilizes carbon construction to the maximum extent allowed by regulations. These technical papers, written between 1971 and 2003, offer what Smith believed to be the best and most practical nuggets of racing chassis and suspension design information.
This thesis details an analytical approach to an innovative suspension system design for implementation to the Formula SAE collegiate competition. It focuses specifically on design relating to geometry, mathematical modeling, energy element relationships, and computer analysis and simulation to visualize system behavior. The bond graph approach is utilized for a quarter car model to facilitate understanding of the analytical process, then applied to a comparative analysis between two transverse half car models. The second half car model contains an additional transverse linkage with a third damper, and is compared against the baseline of the first half car model without the additional linkage. The transverse third damper is an innovative design said to improve straight-line tire contact during single-sided disturbance, help mitigate the adverse effects of squat and dive, while not inhibiting the function of the anti-roll bar in cornering capability. Additional work is done investigating an optimization of suspension geometry through mathematical modeling in MATLAB of a four-bar linkage system. This code helps visualize the complex motion of the upright and calculates the wheel camber rate and variation to compare against tire data analysis to match maximum tire performance characteristics with camber angle.
Several standardized courses for Formula SAE (FSAE) testing are introduced and described with sufficient detail to be reproduced by any Formula SAE team. Basic analysis methods for the courses are given as well as explanations of how those analyses could be used. On-car data from the Global Formula Racing (GFR) SAE cars is used to verify the analysis methods, give estimates to unknown variables, and show the relevance of the standard testing courses. Using the courses and methods described in this paper should allow standardized comparison of FSAE car performance, as well as provide a method to verify simulations and evaluate changes in vehicle performance from tuning. Instrumentation of all suspension member forces with strain gauge load cells is shown to be an extremely powerful tool for measuring vehicle performance and quantifying vehicle dynamic characteristics. The design and implementation of strain gauge load cells is described in detail to provide a template for reproducing similar results in other vehicles. Data from the GFR 2011 FSAE car is used throughout the paper to: show the design process for making effective suspension member load cells, show the calibration processes necessary to ensure quality data is collected, illustrate the calculation of suspension corner forces, and show the effectiveness of measuring vehicle dynamic characteristics with this technique. Using the methods described in this paper should provide data that allows a more complete and thorough understanding of on-car vehicle dynamics. This data may be used to validate vehicle models.
Discusses the design and development of shock absorbers with emphasis on applications to a Formula SAE race car. The car's combination of very low vehicle mass and large suspension stroke limits the number of appropriate off the shelf damper solutions. To address this issue, the 2006 University of Michigan Formula SAE team designed and developed a custom set of dampers. The team focused on the damper's function in the vehicle and how certain damper performance characteristics affect dynamic response.
This book presents the select proceedings of the second International Conference on Recent Advances in Mechanical Engineering (RAME 2020). The topics covered include aerodynamics and fluid mechanics, automation, automotive engineering, composites, ceramics and polymers processing, computational mechanics, failure and fracture mechanics, friction, tribology and surface engineering, heating and ventilation, air conditioning system, industrial engineering, IC engines, turbomachinery and alternative fuels, machinability and formability of materials, mechanisms and machines, metrology and computer-aided inspection, micro- and nano-mechanics, modelling, simulation and optimization, product design and development, rapid manufacturing technologies and prototyping, solid mechanics and structural mechanics, thermodynamics and heat transfer, traditional and non-traditional machining processes, vibration and acoustics. The book also discusses various energy-efficient renewable and non-renewable resources and technologies, strategies and technologies for sustainable development and energy & environmental interaction. The book is a valuable reference for beginners, researchers, and professionals interested in sustainable construction and allied fields.