This study involves the development of a Suspension system for FSAE vehicles participating in the Combustion Category. The front setup is also introduced with a bar-type Anti-Roll Bar (ARB) to ...manipulate the Understeer and Oversteer response of the vehicle. The initial parametric study was performed with an iterative approach in the spreadsheet. Race-cars also have stiffer suspension i.e.; the ride frequency is above 2 Hz; the reason being that the driver does strict maneuvering on the race track. FSAE vehicles have ARB's for better cornering performance and to manipulate the response of the vehicle mainly understeer and oversteer suiting to the driver. Another advantage is the limitation of camber gain caused by the body roll as it improves the traction. Further, the Kinematic study of all the components in the system was analyzed through IPG Kinematic Software. The focus was made on the variation of Camber Angle, Steer Angle, Track Change, and Roll Angle with and without the ARB incorporation. The calculation for the selection of different bearings is also performed. Considering the previous vehicles and the new design goals, parametrizing of the vehicle is also performed. The overhang of the vehicle plays an important factor in the longitudinal load transfer during the braking and acceleration. Forces experienced by all the components were also extracted from the software. This data is then used as the input parameter for Structural Simulation on CAE platform ANSYS. Material properties of Aluminum 6061 T-6 are used for the Bell Cranks and carbon Steel is used for ARB setup. Static structural simulation is performed on the Front Rocker, Upright and Hub. Specific torsional simulation is done on the ARB considering the axial offset position of the support bearing and the loading point on the blade.
Composite sandwich structures are widely used in transport and energy applications because of their excellent specific strength and fatigue damage resistance. However, the mechanical properties of ...the joint area rely on the structural design. This paper proposes a novel carbon fiber-reinforced polymer sandwich joint in the context of a Formula Student monocoque. A stiffener is introduced to connect carbon fiber panels on both sides, and the geometry of the aluminum honeycomb connecting core is adjusted to improve the stress distribution in the joint panels. A finite element model under a three-point bending load is established based on the progressive damage model and the cohesive zone model. The mechanical properties were compared with conventional joints based on Formula Student three-point bending tests. Specimens were fabricated and tested using t700 carbon fiber prepreg and 3003 aluminum honeycombs to verify the joint’s performance and the accuracy of the finite element model. Experimental results showed that the three-point bending strength of the novel joint increased by 52.27
%
, and the stiffness increased by 101
%
compared to the conventional design. The simulated strength errors of the novel joint and the conventional joint were 4.66
%
, and 13.7
%
, respectively, and the failure modes were consistent with the experimental results, indicating the validity of the finite element model. The novel joint profile is less protruding than the conventional joint and could be widely used for joining or repairing automotive and aircraft components.
This paper deals with the design of an upright using a topological optimization. This type of optimization is a relatively young and rapidly evolving area of computational mechanics that seeks to ...make multiple material savings that cannot be achieved by conventional methods. The optimized upright was utilized in a fully functional prototype of the student formula within the Formula Student competition. The main objective of the optimization was to meet the requirements of the physical properties, weight, stiffness, and strength of the upright. The initial model of the upright was iteratively optimized using topological optimization and a finite element static analysis to obtain the final model. Using the finite element analysis, its behavior in operation within individual load cases was predicted. Symmetry was used to mirror the finished model to obtain the opposite upright of the other side of the car. Finally, the topologically optimized upright was compared with an upright made by conventional methods.
The use of impact attenuators (IA) is important for vehicles as they absorb the kinetic energy exerted from the car crashes to protect the drivers from any possible injuries. Under the framework of ...the Formula Student (FS) competition, we investigate various designs of IA made of aluminum honeycomb material. Specifically, the crushing behavior of the honeycomb structure is investigated from the theoretical point of view and later verified with numerical simulations. To achieve the desired crushing behavior of the aluminum honeycomb structure, apart from the so-called pre-crushing method, another way to pre-process the aluminum honeycomb is proposed. Modification on the aluminum honeycomb is done in a symmetric manner to ensure the same uniform crushing behavior on the two sides of the mirror plane of the car. Different variations presented in this paper shed a light on future aluminum honeycomb IA designs in the context of FS competitions.
The article deals with wheel suspension of formula student. A proposal follows the rules of SAE International. SAE International is an organizer of Formula Student/SAE competition. Races of formula ...student are organized all over the world. This competition is becoming very popular in Central Europe and VŠB - TU Ostrava would like to join this competition in the next year. This article was created during the development of the first generation of Formula Student at VŠB-TU Ostrava.
Vehicle safety is one of the most research fields within the technology. The car industry is developing passive and active safety systems techniques to enhance passenger safety. To scale back ...development costs and test new security architectures, it is recommended to be utilized in the evaluation of initial accident safety calculations under vehicle trials. One device that has succeeded in reducing damage to vehicle structures and repairing damage to passengers because of collisions is that the impact attenuator. Usually, the impact attenuator is created of aluminum, honeycomb, carbon, composite, and tinfoil. But on the other hand, these materials tend to possess high prices. So, we decided to do a numerical test of the impact attenuator employing a recycle that is also made from aluminum alloy. This study aims to research and study the deformation phenomena that occur in impact attenuators with numerical tests.
An impact attenuator, commonly called crash cushion or crash attenuator, could be a part that is accustomed to reduce the damage that happens to the vehicle structure when an accident occurs during a ...vehicle. Recently there are such a significant amount of materials for impact attenuators that are usually fabricated from aluminum, honeycomb, carbon, composite, and tin foil or a mix of those materials to produce maximum protection to the driving force, where these materials tend to own high prices. Meanwhile, the impact attenuator design must be of lightweight material, which may contribute to improving acceleration performance and meeting compatibility with competition rules. So, we decided to try and do a numerical test of the impact attenuator using recycle waste can, which is additionally made from aluminum alloy. This research mainly deals with the event and style of impact attenuators for student formula cars that listen to economics, innovation, and easy making.
This article summarises the development and experience of the Formula Student race car engine from 2018. According to the technical rules of Formula Student after the change in 2017, this engine ...adopts a new design concept, employs a 690-mL single-cylinder engine as the base, and applies ‘response enhancement technology’ with supercharging as the core to achieve a high-power output, a wide high-torque range and an excellent response capability. During the development, various studies on the dynamic performance of the vehicle and the engine were conducted, including vehicle dynamics analysis and track simulation, parameter matching of the supercharger and the engine, control strategy design, and the intake and exhaust system design. This research builds a supercharger air flow and efficiency test bench and an engine performance test bench. Test results show that the developed engine can output 122% of the original power and 120% of the original torque with a 20-mm diameter intake restrictor. Compared with previous generation race cars with a turbocharged four-cylinder engine, the new race car‘s 0–100 km/h acceleration time is shortened by 0.2 s, the torque response time under typical condition is shortened by 80%, and the lap time of the integrated circuit is reduced by 7%.
During car races, strong vibrations appear in the chassis of the vehicle, due to the high power created by the engine which are then transmitted and, therefore, affect the driver’s condition. The ...study of these vibrations is a subject frequently addressed by researchers, analyzing the influence of different parameters on the forces to which the pilot’s body or certain sensitive body parts are subjected. In this paper, we analyze the particular case of a racing car made to meet safety requirements in the event of an accident. For the analysis of the forced vibrations induced by the running track, the finite element method was used. This method proved to be a useful and stable modeling and analysis method, validated by practical applications. A standard-equipped racing car with a mannequin inside was studied. Once the natural frequencies of the structure were determined, the response of some points of the mannequin’s body to the movement caused by the running track or the engine was analyzed. Modeling and discretization were performed using well-known classical procedures. The obtained results revealed the parameters that can negatively influence the body of the mannequin which were communicated to the design team. The conclusion of this study is a racing car that was successfully used in Formula Student competitions.
This paper reviews the design and test results for the main passive safety feature of Formula-type (Formula Student class) open-wheel racing cars: the tubular spaceframe chassis. Formula Student is ...an international competition for engineering students and young athletes, who work in teams to design racing cars, assemble them from scratch, and then race them. This paper presents a chassis strength analysis, the results of head-on and lateral crash tests, and torsional stiffness calculations for the chassis of a racing car used by the team representing the Shukhov Belgorod State Technological University, as proof that this particular structural design is safe for future use.
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