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
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
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
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
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
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
Model DetailsModel Details
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
Model DetailsModel Details
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
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
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
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
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
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
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