Patrick Bandeira de MelloFelipe Moura Fontes Novo

Analysis and Simulation of Rear

Suspension Architecture for a Formula SAE

Vehicle Using ANSYS Software

Problem Description

Methodology

Goals

Conclusion and Next

Steps

Company Overview

Formula SAE

2006 2007 2008 2009 2010

Competition Layout:

Friday:

Morning: Engineering Design………………150 points

Afternoon: Cost Analysis..…………………. 100 points

Business Presentation..……………………..075 points

Saturday:

Morning: Skidpad……………………………. 050 points

Morning: Acceleration Event………………. 075 points

Afternoon: Autocross Event……………….. 150 points

Sunday:

Endurance Event…………………………….. 300 points

Fuel Economy Event………………………… 100 points

Formula SAE

Needs for a Formula SAE Rear Suspension Design:

Ease of Adjustability

Ease of Maintenance

Lower Mass

Low Compliance

Low Cost

Short amount of time

available between events

Increased Vehicle

Performance and

Predictability

Resource Management

and Cost analysis

evaluation

Formula SAE

Problem Description

Methodology

Goals

Conclusion and Next

Steps

Company Overview

Identifying the problem

- Data Acquisition

- Compliance leading

to unpredictable

behaviour

- Validation

Problem Description

Methodology

Goals

Conclusion and Next

Steps

Company Overview

Development

Double Wishbone H-arm & Camber Link

H-arm & Wishbone

Based on Data Acquisition, for the following conditions:

1 - Positive Longitudinal Acceleration of 1.2g

2 - Positive Longitudinal Acceleration of 0.8g and Lateral

…..Acceleration of 1.4g

3 - Lateral Acceleration of 1.75g

4 - Negative Longitudinal Acceleration of 0.35g and Lateral

…..Acceleration of 1.2g

5 - Negative Longitudinal Acceleration of 0.35g

Vehicle Dynamics Load Case Calculations

Spreadsheet based on Lateral and Longitudinal Load Transfer

Vehicle Dynamics Load Case Calculations

Analysis Method

Control Arms Wheel Carrier

Computational capacity saving

SAE coordinate system

Better mesh refinement

Mesh

230k nodes

Loads

Cylindrical support fixed in

axial direction.

Not considering Brake Caliper

Results

Deformation Stress (Von Mises)

Contacts

Joints

Meshing

80k nodes

Meshing

Loads

Results

Deformation

Stress (Von Mises)

Results

Deformation

Stress (Von Mises)

Results

Deformation

Stress (Von Mises)

Results

Analysis Data & Decision Matrix

Problem Description

Methodology

Goals

Conclusion and Next

Steps

Company Overview

Conclusion and Next Steps

Suspension Architecture:

1st place: Double Wishbone

2nd place: H-arm and Wishbone

3rd place: H-am and Camber Link

Next Steps:

Overall System Validation

System Mass Reduction

We’d like to thank

Questions ?