Research, Design and Manufacturing of Formula Student Racecar.
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Transcript of Research, Design and Manufacturing of Formula Student Racecar.
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Research, Design, Manufacturing of Formula Student Racecar
Team Members:
- Shreeraj Kurkure (4626)
Team Name:- Triumphant Racers
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- Shreeraj Kurkure
1. VEHICLE DYNAMICS
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Design Objectives Develop most efficient Suspension configuration. Reliable Steering geometry. Wheel Alignment – Better Traction. High Acceleration Performance. Identify relevant design parameters – Load Transfer. Real-time Simulation. Manufacturabilty & Simplicity. Driver Comfort. Maintain easy adjustability for further tuning. LAP Concept.
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Design Requirements Minimum 60” wheel base
Unequal front & rear track widths Minimum 1” ground clearance Minimum 2” total suspension travel Template must pass through frame Spherical bearings must be in double shear Design must handle applied loading
Rate of camber angle change with respect to both body roll and wheel displacement
Design Goal
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Design Features Double Wishbone with 4-wheel Independence. Unequal, Non-parallel Control Arms. Length Adjustablilty. - Threaded Chassis Mounts. Camber Adjustabilty. - Aluminium shims. Anti-Roll Bars. Push-rod actuated Dual-Shock Monotube Dampers at
Front. Pull-rod actuated Mono-Shock Monotube Damper at Rear. No REIB.
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Design Methodology Considerations:-1. Car Total Mass = 300kg (with 68kg driver)2. Track Width (F/R) = 1260/1160 mm3. Wheelbase = 1680 mm4. Total Mass Distribution = 48% (Front) 52% (Rear)5. Natural Frequency = 2 (F)/2.2 (R) Hz6. Tire Rate = 90000N/m7. Tire Deformation at Max. Load Transfer = 6mm8. Rim Size = 13 inches9. Lateral Acceleration = 1.5g10. Total Mass CG Height = 275mm
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Step-1: Determination of CG and Static Loading Unsprung Mass (Wheel Assembly+Tires+A-arms):- Front = 10.5kg per wheel Rear = 11.75kg per wheel Sprung Mass:- Suspension Assembly = 11.3kg Steering Assembly = 6kg Pedal Assembly = 8kg Engine+Gearbox+Drivetrain = 80kg Chassis+Seat+Bodyworks = 68kg Total Car Mass = 300kg (with 68kg driver)
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Total Mass CG Co-ordinates:- From Front Axle = 873.6 mm From Rear Axle = 806.4 mm Height from ground = 275mm
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Step-2: Front View Swing Arm Length and Roll Center Location
Roll Center height:- Front = 38.4mm above groundRear = 66mm above ground
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Step-3 : Estimation of Rates
Motion Ratio(F/R) = 1.4/1.2 Ride Rate(F/R) = 19423.38N/m / 25317.5N/m Wheel Rate(F/R) = 24738.23N/m / 36331.34N/m Spring Rate(F/R) = 12637.186N/m / 24535.92N/m Roll Stiffness:- 1. Due to Tires(F/R) = 1426.57N/roll / 1056.31N/roll 2. Due to Springs(F/R) = 451 N/roll / 758 N/roll Max Body Roll Angle = 2.35degrees
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Suspension Dynamics Analysis in OptimumK Software
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Final Suspension Design
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Manufacturing Control Arms
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Push Rod Rocker
Sway Bar
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Manufacturing Suspension System – Front Assembly
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Geometry Testing & Perfomance Evaluation
Dynamic Camber Change Load Transfer along 3 axes Damper & ARB Effectiveness
Jounce & Rebound Body Roll Total Damping Offered
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Future Testing PlansStrain gauge and accelerometer data logged during driving
Mychron 3 data logger with internal Accelerometer
Strain gauges