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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.
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.
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.
In this book, the reader learns the essential differences to the passenger car through the analysis divided according to assemblies. This gives him the tools to apply the detailed knowledge he has acquired to the design and development of competition vehicles. The chassis determines the driving behaviour and thus the "DNA" of a racing vehicle like no other assembly. Starting with the tyre - the decisive mechanical component - all the components of the wheel suspension including steering and braking system are presented and discussed. The focus is on the double wishbone and suspension strut axles. The design of wheel suspensions starts with kinematic considerations, leads via component design to considerations of the vehicle dynamics. Ultimately, the maximum forces of the tires in the transverse and circumferential directions are to be exploited while keeping the vehicle controllable. Due to the detailed, in-depth presentation, the work is just as suitable for the interested motorsport enthusiast as it is for the engineer in practice who is dealing with questions relating to racing suspensions. The formula material is prepared in such a way that the book can also be used as a reference work.
This paper will explore the features that optimize suspension performance for a Formula SAE racecar, focusing on suspension geometry. Employing research and designs from previous year's cars, the suspension will be designed using the iterative design process. To help with this process, multiple programs and methods will be used. When the design is finalized it will be built and installed on the 2019 Viking Motorsport's Formula SAE car.
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.
Reducing weight while maintaining structural integrity is one of the key challenges Formula SAE teams face as they try and design the suspension of the formula car. The purpose of this paper is to present experimental data on designing and optimizing a carbon fiber suspension system for formula cars. The reason carbon fiber suspensions are favored over the current steel suspensions is because of they can reduce the weight of the suspension by 50%. Pull tests on an Instron machine were performed on over 15 specimens composed of a carbon fiber tube with an aluminum insert bonded to each end. Loctite E-120HP epoxy was used and the surface preparation, bond gap, and bond length were varied to find the optimal bond strength. An average bond strength of 2,382.6 pounds per square inch was determined for specimens with surface preparation. Furthermore a bond gap of 0.0065 to 0.008 inches was found to give the strongest bond.