Redesign of Lotus Europa Front Suspension
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Transcript of Redesign of Lotus Europa Front Suspension
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Redesign of Lotus Europa Redesign of Lotus Europa Front SuspensionFront Suspension
ME 450: Finite Element AnalysisME 450: Finite Element AnalysisSpring 2007Spring 2007
Presented by: Presented by: Bart Sudhoff, Zachary Lightner, Jim Bart Sudhoff, Zachary Lightner, Jim
Milligan, Brian Schludecker, David GilesMilligan, Brian Schludecker, David Giles
Dr. NemaDr. Nema4/30/20074/30/2007
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Summary & IntroductionSummary & Introduction
Redesign Front Suspension Upper Control Redesign Front Suspension Upper Control ArmArm
Top Speed Increase: 120 to 200 MPHTop Speed Increase: 120 to 200 MPHDesign Issues:Design Issues:
New weight of car due to increased engine New weight of car due to increased engine sizesize
New handling characteristicsNew handling characteristics
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Original DesignOriginal Design
Built in 1970Built in 1970 1470cc OHV 4 1470cc OHV 4
Cylinder Engine – Cylinder Engine – 78HP78HP
Front Wheel DriveFront Wheel Drive 4-Speed 4-Speed
TransmissionTransmission Curb Weight: 1320-Curb Weight: 1320-
1570lbs1570lbs Top Speed 120 MPHTop Speed 120 MPH
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New DesignNew Design
Engine: Lexus V8 4.0L Quad CamEngine: Lexus V8 4.0L Quad CamTransmission: Porsche 5-SpeedTransmission: Porsche 5-SpeedSuspension: New Design of Lower/Upper Suspension: New Design of Lower/Upper
Control Arms, Springs, ShocksControl Arms, Springs, ShocksFactor of Safety of 5Factor of Safety of 5Light WeightLight WeightMinimal DeformationMinimal Deformation
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Theoretical BackgroundTheoretical Background
Decomposition of Decomposition of model into stiffness, model into stiffness, force matricesforce matrices
Solution in form of Solution in form of nodal displacement nodal displacement matrixmatrix
4-node tetrahedral 4-node tetrahedral element element displacement displacement solutionsolution
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Model DetailsModel Details
Upper and Lower Control arms modeled Upper and Lower Control arms modeled using Pro/Eusing Pro/E
ConstraintsConstraintsFix – about the mounting holesFix – about the mounting holesForces applied at ball jointForces applied at ball joint
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Model DetailsModel Details
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Model DetailsModel Details
Load Case: X Y Z
Vertical Bump 0g 3g 0g
Rebound 0g 2g 0g
Pothole 0g 4g 1.5g
Force (N)
Load Case: X Y Z
Vertical Bump 0 -1024.5 -3166.3
Rebound 0 683 2110.9
Pothole -4221.8 -1366 -768.3
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Model DetailsModel Details
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ResultsResults
2” thick arm2” thick armStress - 20.06 MPa Stress - 20.06 MPa Deformation - .102 mm Deformation - .102 mm Safety Factor – Greater than 10Safety Factor – Greater than 10
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ResultsResults
1.75” thick arm1.75” thick armStress - 25.1 MPa Stress - 25.1 MPa Deformation - .128 mm Deformation - .128 mm Safety Factor – Greater than 5Safety Factor – Greater than 5
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ResultsResults
1.75” thick arm with relief1.75” thick arm with reliefStress - 18.9 MPa. Stress - 18.9 MPa. Deformation - .131 mm Deformation - .131 mm Safety Factor – Greater than 5Safety Factor – Greater than 5
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ResultsResults
1.5” thick arm with relief1.5” thick arm with reliefStress - 24.4 MPa Stress - 24.4 MPa Deformation - .184 mm Deformation - .184 mm Safety Factor – Greater than 5Safety Factor – Greater than 5
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ResultsResults
1.5” thick arm with relief1.5” thick arm with reliefVertical BumpVertical Bump
Stress - 3.82 MPa Stress - 3.82 MPa Deformation - .0229mm Deformation - .0229mm Safety Factor – Greater than 10Safety Factor – Greater than 10
ReboundReboundStress - 14 MPaStress - 14 MPaDeformation - .106mm. Deformation - .106mm. Safety Factor – Greater than 10Safety Factor – Greater than 10
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ConclusionConclusion
Chose 1 ½” control arm with relief cutsChose 1 ½” control arm with relief cutsPassed factor of safety testsPassed factor of safety testshas allowable deformationhas allowable deformationWill allow car to go 200 mphWill allow car to go 200 mph