Accessing RAVE hardware for PLATO PIC Ulisse Munari Tomaz Zwitter.
Titanium safety cages in the automotive racing industry · Tomaz Bucar, Ph.D. INTRODUCTION TITANIUM...
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Titanium safety cages in the automotive racing industry Tomaz Bucar, Ph.D.
Transcript of Titanium safety cages in the automotive racing industry · Tomaz Bucar, Ph.D. INTRODUCTION TITANIUM...
Titanium safety cages in the
automotive racing industry
Tomaz Bucar, Ph.D.
INTRODUCTION
TITANIUM IN AUTO INDUSTRY
Increasing demand for more fuel-efficient and
environmentally friendly road vehicles.
In addition to weight savings, the visual appearance as
well as performance with titanium attracts customers.
Weight reduction leads to fuel
savings of a vehicle.
1% reduction in mass can result in
0.7% reduction in fuel consumption.
INTRODUCTION
TITANIUM IN AUTO INDUSTRY
Several automotive components can be replaced with
titanium:
engine valves
valve springs and retainers
connecting rods
suspension springs
exhaust systems
turbocharger compressor wheels
various fasteners.
The application of titanium and its alloys to automotive
components has grown in the last years.
INTRODUCTION
TITANIUM IN AUTO INDUSTRY
High price of titanium has prevented realization of all
these applications in mass-produced passengers cars.
A lot of applications were
realized in racing cars where
weight reduction is critical.
Titanium has a long record of
success in performance and
racing cars (beginning of the
1980s).
INTRODUCTION
AUTOMOTIVE RACING INDUSTRY
Designers are constantly trying to save a few extra
grams of weight in their design.
Material choice plays a large part in the design equation.
Safety cages represent an
attractive entry point for
titanium into the automotive
racing industry.
INTRODUCTION
SAFETY CAGES
Multi-tubular structure installed in the cockpit and fitted
close to the bodyshell of a wehicle:
they help to stiffen the chassis
reduce the deformation of the bodyshell
(chassis) in case of an impact
used in purpose-built race cars and cars
modified for racing
many different roll cage designs
depending on the application
different racing organizations have
different specifications and regulations.
INTRODUCTION
SAFETY CAGES
Minimum configuration of a safety cage is defined
according to the regulations:
FRONT
ROLLBAR
MAIN
ROLLBAR
DOORBARSREINFORCEMENTS
Weight of standard steel safety cage is more than 50kg!
TITANIUM SAFETY CAGES DEVELOPMENT
TITANIUM SAFETY CAGES
With direct substitution of steel cage with titanium an
immediate weight reduction of 40% can be achieved.
But safety cages are actually STIFFNESS CONSTRAINED!
Successful application of titanium alloys for safety cages
demands a thorough consideration of titanium's unique
properties.
Low modulus of titanium requires components redesign
in this stiffness limited application.
TITANIUM SAFETY CAGES DEVELOPMENT
DEVELOPMENT PROCEDURES
The development starts with the safety cage design
made by the help of CAD.
ORIGINAL STEEL
SAFETY CAGE
REDESIGNED TITANIUM
SAFETY CAGE
Original steel safety cage was redesigned considering
titanium unique properties.
TITANIUM SAFETY CAGES DEVELOPMENT
DEVELOPMENT PROCEDURES
The CAD model of the safety cage is the core element
for all subsequent numerical analyses and test methods.
FE MODEL
Next step is 3D CAD
model discretization.
Attention to details
discretization.
TITANIUM SAFETY CAGES DEVELOPMENT
DEVELOPMENT PROCEDURES
The complete safety cage must be subjected to the
static load tests in accordance with the regulations:
RIGID
CONSTRAIN
Vertical load of F = 75(w+150) [N],
where w [kg] is weight of the car.
Applied on the top of the main
rollbar.
Mounting points are rigidly
constrained.
F
TITANIUM SAFETY CAGES DEVELOPMENT
DEVELOPMENT PROCEDURES
Finishing the CAD model discretization phase,
structural numerical analyses based on the FEM follow.
DEFORMATION STRESS
TITANIUM SAFETY CAGES DEVELOPMENT
DEVELOPMENT PROCEDURES
Finally the first prototype
was made in accordance with
the approved CAD model.
Measurements are carried out
on the standardized testing
device in order to prove
corelation:
FEM TESTINGTESTING DEVICE
CONCLUSION
SUMMARY
Using titanium in safety cages means weight
reduction better results both in the vehicle
performance and fuel efficiency.
Weight reduction of the Porsche GT3 titanium safety
cage compare to steel one is 35% (from 41 to 26.5kg)
Weight is reduced in the upper part of the vehicle.
