To redesign the front suspension To redesign the front suspension rocker for the #4 Delphi Panther rocker for the #4 Delphi Panther Racing Indycar.Racing Indycar.

To reduce weight of front rockers by To reduce weight of front rockers by ½ a pound each.½ a pound each.

Constructed using Aluminum rather Constructed using Aluminum rather than Steel.than Steel.

Rocker used in front suspension for Indy Rocker used in front suspension for Indy Racing LeagueRacing League

Maximum Load = 7000 lbsMaximum Load = 7000 lbs Verified by DAG team at Panther RacingVerified by DAG team at Panther Racing

Constructed rocker in Pro-engineerConstructed rocker in Pro-engineer Analyzed in ANSYS WorkbenchAnalyzed in ANSYS Workbench

Analyzed stresses on steel rockerAnalyzed stresses on steel rocker

Resigned rocker in order to minimize Resigned rocker in order to minimize stressesstresses

Constructed rocker from AluminumConstructed rocker from Aluminum

Centrifugal Centrifugal

ForceForce

Solid 92 (Tetrahedral Solid)Solid 92 (Tetrahedral Solid) 10 Nodes, 3-D Space10 Nodes, 3-D Space DOF: UX, UY, UZDOF: UX, UY, UZ

WORKBENCH default elementWORKBENCH default element

Local equation of Force:Local equation of Force:{f} = [K]{u}

Local equation (expanded 2D)Local equation (expanded 2D)

Transformation MatrixTransformation Matrix

Finding Global Stiffness Matrix (Moaveni)Finding Global Stiffness Matrix (Moaveni)

Global Equation (expanded 2D)Global Equation (expanded 2D)

Stress-Displacement RelationshipStress-Displacement Relationship

Stress-Strain RelationshipStress-Strain Relationship

Pro-Engineer Solid ModelsPro-Engineer Solid Models Converted to SAT format for ANSYS Converted to SAT format for ANSYS

WorkbenchWorkbench

R5.000+2.000 mm

R5.000+1.350 mm

4.521+3.099 mm

Fine MeshFine Mesh 47,039 Nodes47,039 Nodes 24,657 Elements24,657 Elements

Fixed SupportFixed SupportZero DisplacementZero Displacement

Rotational MotionRotational Motion

OnlyOnly Force of 7000 lb Force of 7000 lb

Directed OutwardDirected Outward

Original RockerOriginal RockerSteelSteel

Maximum Maximum StressStress88.4 ksi88.4 ksiBoth sides of Both sides of

hoophoop

Modified RockerModified RockerAluminumAluminum Increased Radius of Increased Radius of

hole by 1.35 mm hole by 1.35 mm Increased Outside Increased Outside

Radius by 2 mm Radius by 2 mm Reduced StressReduced Stress

79.28 ksi79.28 ksi

Further Modified Further Modified RockerRockerAluminumAluminumIncreased Increased

Thickness by 3.099 Thickness by 3.099 mmmm

Reduced StressReduced Stress65.05 ksi65.05 ksi

Redesigning the front suspension rocker Redesigning the front suspension rocker has given Panther Racing an edge on the has given Panther Racing an edge on the competition by reducing the weight of the competition by reducing the weight of the car while keeping the driver safe. car while keeping the driver safe.

Even though it is a very small amount of Even though it is a very small amount of weight that is being lost, anything that weight that is being lost, anything that can be lost from the car in terms of weight can be lost from the car in terms of weight can give that extra thousandth of a can give that extra thousandth of a second that is needed in order to beat the second that is needed in order to beat the competition. competition.

Modifications of Original Steel Rocker Modifications of Original Steel Rocker reduced stresses by approx. 30%reduced stresses by approx. 30%

7000 Series Aluminum could 7000 Series Aluminum could successfully be used!successfully be used!

Maximum Stress = 65 ksiMaximum Stress = 65 ksi Increasing Diameters, Radius, and Increasing Diameters, Radius, and

Thickness Reduce Stress Around Thickness Reduce Stress Around HoleHole

Incropera, Frank, David Dewitt, and Incropera, Frank, David Dewitt, and Theodore Bergman. Fundamentals of Heat Theodore Bergman. Fundamentals of Heat and Mass Transfer. 6th. Hoboken NJ: Wilet and Mass Transfer. 6th. Hoboken NJ: Wilet & Sons, 2007. & Sons, 2007.

Nematollahi, Khosrow. "Oncourse, ME Nematollahi, Khosrow. "Oncourse, ME 450." Scheduled Reading and 450." Scheduled Reading and Assignments. IUPUI. 23 Nov 2007 Assignments. IUPUI. 23 Nov 2007 <https://oncourse.iu.edu/access/content/u<https://oncourse.iu.edu/access/content/user/knematol/Filemanager_Public_Files/ser/knematol/Filemanager_Public_Files/ME450LectureNotesCh13r>. ME450LectureNotesCh13r>.