2002 FSAE Suspension Team

Final Presentation
Faculty Advisor: Prof. Norman Miller
Graduate Advisor: Marten Dane

Bernard Norris Brian Pigg

Matt Polley Yezin Taha
Introduction
 Student car competition
 Problem Statement
 Designand develop a new suspension
system for 2002 SAE Formula
competition.
Project Objectives
 Complete Literature Search
 Analyze 2001 Suspension
 Create 2002 Suspension Design
 Analyze 2002 Suspension Design
 Create Design Methodology
Literature Search
 Non-technical publications
 Introductionto suspension components
and terminology
 Common performance suspensions

 Technical publications
 Design parameters
 Applications of composites
Basic Suspension
Basic Suspension
 Analysis of 2001 Suspension
 Current Design Concerns
 Designed around limitations
 Oversized brakes and
uprights
 Poor suspension geometry
 Bump-steer and scrub radius
 Large unsprung mass
 Analysis of 2001 Suspension
 Pro Engineer
 Generated suspension components
 NASTRAN 4D
 Assembled suspension components
 Animated suspension assembly

 ANSYS
 FEA of existing upright
Analysis of 2001 Suspension
 Pro Engineer
 Modeled Major Components
 A-arms
 Upright

 Bell crank
Analysis of 2001 Suspension
 Assembled rear suspension
Analysis of 2001 Suspension
 Assembled front suspension
Analysis of 2001 Suspension
 NASTRAN 4D
 Animated Pro E Components
Analysis of 2001 Suspension
 Provided suspension response
 Effectivespring rate
 Camber gain

 Caster gain

 Bump steer
Analysis of 2001 Suspension
 Effective Spring Rate of Rear Wheel
0.8
0.79
0.78
0.77
Kwheel/Kspring

0.76
0.75
0.74
0.73
0.72
0.71
0.7
-1.5 -1 -0.5 0 0.5 1 1.5

Wheel Displacement (Inches)

Analysis of 2001 Suspension
 Effective Spring Rate of Front Wheel
0.75

0.7
Kwheel /Kspring

0.65

0.6

0.55

0.5
-2 -1.5 -1 -0.5 0 0.5 1 1.5 2

Wheel Displacement (in)

Analysis of 2001 Suspension
 Front Wheel Response
8

4
Wheel Deflection (Degrees)

2
Bump Steer
Camber
0
Caster

-2

-4

-6

-8
-2 -1.5 -1 -0.5 0 0.5 1 1.5 2
Wheel Displacement From Ride Height (Inches)
Analysis of 2001 Suspension

 ANSYS
 Consulted Professor
Thomas
 Obtained NCSA access

 Imported solid model

 Meshed with solid

elements
 Analysis of 2001 Suspension
 Critical Loading Conditions
 Acceleration, Cornering, Braking, Jounce
 Applied Loads
 2W Vertical
 1W Lateral

 1W Longitudinal
Analysis of 2001 Suspension

Yield Stress=150 MPa

Max Stress=109 MPa
2002 Suspension Design
 Generate Design Parameters
 Wheelbase
 Track Width
 Center of gravity location
 Roll center
 Steering
 Anti-pitch
 Caster
 Camber
 Spring Rate
2002 Suspension Design
 Design critical suspension geometry
 Determine component dimensions
 Pro Engineer
 Modeled major components
2002 Suspension Analysis
 Assembled rear suspension
2002 Suspension Analysis
 Assembled front suspension
2002 Suspension Analysis
 Animated suspension assembly
2002 Suspension Analysis
 Effective rear spring rate
0.8
0.78
0.76
0.74
Kwheel /Kspring

0.72
0.7
0.68 2002

2001
0.66
0.64
0.62
0.6
-2 -1.5 -1 -0.5 0 0.5 1 1.5 2
Wheel Displacement (Inches)
2002 Suspension Analysis
 Effective front spring rate
0.75

0.7 2002

2001
Kwheel/Kspring

0.65

0.6

0.55

0.5
-2 -1.5 -1 -0.5 0 0.5 1 1.5 2
Wheel Displacement (in)
2002 Suspension Analysis
 Caster
10
9
2002
8
7 2001
6
Caster (Degrees)

5
4
3
2
1
0
-1
-2 -1.5 -1 -0.5 0 0.5 1 1.5 2
Wheel Displacement (Inches)
2002 Suspension Analysis
 Camber
0
2002
-1 2001
Camber Angle (Degrees)

-2

-3

-4

-5

-6
-2 -1.5 -1 -0.5 0 0.5 1 1.5 2
Wheel Displacement (Inches)
2002 Suspension Analysis
 Bump Steer
8
2002
6
2001
Bump Steer (Degrees)

-2

-4

-6
-2 -1.5 -1 -0.5 0 0.5 1 1.5 2

Wheel Displacement (Inches)

2002 Suspension Analysis
 ANSYS
 Designed new
upright in Pro E
2002 Suspension Analysis
 Importsolid model into ANSYS
 Same loading conditions

Max Stress = 5000 psi

Yield Stress = 20000 psi
2002 Suspension Analysis
 Use of Composites
 Construct A-arms using composites
 Benefits
 Reduce weight
 Increased stiffness
 Material Selection
 Carbon-epoxy tubes
 Aluminum Inserts
 Joining
 Metal – Carbon bonding
 Pull out test data
Design Methodology
 Determine track-width and wheelbase
 Determine roll center height
 Determine shock and steering system
locations
 Consult with chassis and powertrain
group
 Design upright and analyze with FEA
Questions