2012 Formula SAE Outboard Suspension Jose Colin Efe Yildirim Chip Larson Rick Rickert Carole Gayley Thomas McCall Industry Advisor: Evan Waymire
Academic Advisor: Lemmy Overview Background Mission Statement Design Requirements Off the Shelf or Custom Custom Design options Calculations Design Decision
Final Design FEA Analysis Challenges and Solutions Conclusion Background Each year, Viking Motorsport (VMS) designs builds and tests an open wheel racecar. FSAE OS Team will redesign the outboard suspension for MY12. 2012 Competition: June 20-23 in Lincoln, NE
Functional need for center-lock wheels Competition in Nebraska-it may rain at a moments notice, so wheel change would be quicker Less rotational inertia Mission Statement FSAE-OS Team will design, validate and produce a new outboard suspension that will weigh less, have reduced part
machining time and cost that integrates a centerlock system. Design Requirements 2011 & 2012 parts are interchangeable Back-up system in case of failure Centerlock nut retention with two threads exposed FSAE rule Hub Weight
Target: 2lb Must withstand 2G cornering load Customer requirement Design Requirements Ease of Manufacturing Machining time: 80 min Hub cost
$200 each Service life 2 years Installation torque No more than 300 ft.lbf Off the Shelf Option Taylor Race FSAE/DSR hub and upright assembly
Aluminum pilot Final Design Final Design Final Design Analysis Front Hub Bending 2G cornering
Final Design Analysis Clamp force Final Design Analysis Upright camber compliance 2G cornering load Upper deflection: 0.063 mm Lower deflection: 0.152 mm
Total deflection: 0.047* Camber compliance : 0.024*/G Final Design Analysis Upright cornering Final Design Analysis Upright braking
Final Design Analysis Brake hat, clamped Final Design Analysis Brake hat , no clamp load Challenges/Solutions High fatigue cycling in hub requires infinite life
The hubs were designed using experimental fatigue data for similar materials and conservative assumptions No dynamic vehicle data Typical dynamic vehicle data from similar applications No budget Prototype parts were donated by Viking Motorsports, Warn Industries, ARE Manufacturing, Beaver Heat Treat, Dr. Lemmy Meekisho and Zdenek Zumr. Challenges/Solutions Due to the necessity of donated manufacturing services, parts
of a new design will not be ready to test and use on the car within the same year New designs tested and used on the next model year Conclusion The Product Design Specification is the roadmap for the final design. Its completeness in satisfying known and unknown customer requirements is directly related to how good the final design is. Majority of time was spent working on non-design details
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