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Redesign of an FSAE Race Car's Steering And University of Southern Queensland Faculty of Engineering and surveying Redesign of an FSAE Race Car’s Steering and Suspension System A dissertation submitted by Jock Allen Farrington In fulfilment of the requirements of Courses ENG4111 and ENG4112 Research Project Towards the degree of Bachelor of Mechanical Engineering Submitted: October, 2011 i Abstract The chosen project is based on the redesign of the steering and suspension system for the University of Southern Queensland’s 2008 Formula SAE (Society of Automotive Engineers) or FSAE vehicle. In 2008 USQ’s FSAE team was forced to abandon the competition due to a crash into a barrier which was thought to have been caused by the car’s suspension and steering system. If USQ plans to enter a car into future FSAE competition it seemed appropriate that the current suspension and steering system be revised. The project aimed to uncover any problems with the 2008 vehicle and then use these findings, coupled with appropriate research, to create a new steering and suspension system that possesses improved performance. Although there is no team for the competition this year it is intended that all work completed will be able to be utilised by future groups in years to come. Completion of the project has seen the design of geometry for the suspension arms, suspension actuation mechanisms, uprights as well as the steering rack and arms. Additionally, concepts in the way of 3d models have been established for the suspension and steering systems. ii University of Southern Queensland Faculty of Engineering and Surveying ENG4111 Research Project Part 1 & ENG4112 Research Project Part 2 Limitations of Use The Council of the University of Southern Queensland, its Faculty of Engineering and Surveying, and the staff of the University of Southern Queensland, do not accept any responsibility for the truth, accuracy or completeness of material contained within or associated with this dissertation. Persons using all or any part of this material do so at their own risk, and not at the risk of the Council of the University of Southern Queensland, its Faculty of Engineering and Surveying or the staff of the University of Southern Queensland. This dissertation reports an educational exercise and has no purpose or validity beyond this exercise. The sole purpose of the course pair entitled “Research Project” is to contribute to the overall education within the student's chosen degree program. This document, the associated hardware, software, drawings, and other material set out in the associated appendices should not be used for any other purpose: if they are so used, it is entirely at the risk of the user. Professor Frank Bullen Dean Faculty of Engineering and Surveying iii Certification I certify that the ideas, designs and experimental work, results, analyses and conclusions set out in this dissertation are entirely my own effort, except where otherwise indicated and acknowledged. I further certify that the work is original and has not been previously submitted for assessment in any other course or institution, except where specifically stated. Jock Allen Farrington Student Number: 0050086654 ____________________________ Signature ____________________________ Date iv Acknowledgements I would like to sincerely thank his supervisor Mr Chris Snook for his helpful guidance and assistance throughout the duration of this project. Many thanks also go to the University of Southern Queensland workshop technicians, Adrian Blokland and Mohan Trada for facilitating access to the 2008 Formula SAE vehicle in the laboratory and for their aid in setting up this laboratory for the project. Many thanks also go to the USQ engineering students who assisted in the resurrection and analysis of the 2008 vehicle. Lastly, I would also like to thank my family and friends for their help and support throughout the project. v Contents CHAPTER 1 - INTRODUCTION ..................................................................................... 1 1.1 Problem Definition ....................................................................................................... 1 1.2 Project Objectives ........................................................................................................ 2 1.3 Overview of the Formula SAE competition .................................................................. 3 1.3.1 Judging ................................................................................................................. 3 1.3.2 Vehicle Requirements .......................................................................................... 5 1.3.3 Suspension Requirements .................................................................................... 5 1.3.4 Steering Requirements ......................................................................................... 6 1.4 Suspension and Steering System Definition ................................................................. 7 1.5 Dissertation Overview .................................................................................................. 9 CHAPTER 2 – LITERATURE REVIEW ........................................................................... 11 2.1 Chapter Overview....................................................................................................... 11 2.2 Objective of the Suspension System .......................................................................... 11 2.3 Fundamental Concepts............................................................................................... 12 2.3.1 Load Transfer ...................................................................................................... 12 2.4 Modern Day Suspension Configurations .................................................................... 18 2.5 Objective of the Steering System ............................................................................... 27 2.6 Fundamental Concepts............................................................................................... 28 2.6.1 Geometry ........................................................................................................... 28 2.6.2 Steering Behaviours ............................................................................................ 31 2.7 Modern Day Steering Configurations ......................................................................... 33 2.8 Existing Design Procedures......................................................................................... 36 2.9 Design Recommendations .......................................................................................... 43 2.10 Chapter Summary....................................................................................................... 47 vi CHAPTER 3 – ANALYSIS OF THE 2008 VEHICLE .......................................................... 48 3.1 Chapter Overview....................................................................................................... 48 3.2 Analysis Process ......................................................................................................... 48 3.3 Physically Visible Issues .............................................................................................. 50 3.4 Underlying Issues ....................................................................................................... 52 3.5 Chapter Summary....................................................................................................... 54 CHAPTER 4 – DESIGN PLAN AND FOUNDING DECISIONS ........................................... 55 4.1 Chapter Overview....................................................................................................... 55 4.2 Project Design Plan ..................................................................................................... 56 4.3 Performance Targets .................................................................................................. 59 4.4 Founding Design Decisions ......................................................................................... 62 4.4.1 Type of Suspension ............................................................................................. 62 4.4.2 Tyres and Wheels ............................................................................................... 64 4.4.3 Geometrical Allocations ..................................................................................... 66 4.5 Chapter Summary....................................................................................................... 68 CHAPTER 5 – SUSPENSION GEOMETRY ..................................................................... 69 5.1 Chapter Overview....................................................................................................... 69 5.2 Dimensioning the Uprights ......................................................................................... 69 5.3 Suspension Geometry Evaluation ............................................................................... 72 5.3.1 Initial Decisions ................................................................................................... 72 5.3.2 Wingeo3 Suspension Geometry Program Analysis ............................................. 75 5.3.3 Evaluation Criteria .............................................................................................. 78 5.3.4 Results ................................................................................................................ 79 5.3.5
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