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1Suspension Design and Vehicle Dynamics Model Development Of 1Suspension Design and Vehicle Dynamics Model Development of the Venturi Buckeye Bullet 3 Electric Land Speed Vehicle THESIS Presented in Partial Fulfillment of the Requirements for the Degree Master of Science in the Graduate School of The Ohio State University By Evan D. Maley Graduate Program in Mechanical Engineering The Ohio State University 2015 Master's Examination Committee: Dr. Giorgio Rizzoni Dr. Shawn Midlam-Mohler Copyright by Evan D. Maley 2015 2Abstract For over a dozen years the Buckeye Bullet Electric Land Speed Racing Team has developed electric land speed vehicles that have set numerous national and international land speed records over 300 miles per hour. These vehicles have been powered by various battery chemistries as well as hydrogen fuel cells. The vehicles have been platforms for advanced vehicle research and training for future engineers. Taking such advanced vehicles to tremendous speeds has its difficulties associated with it. There are two related challenges that are covered in this document. The first challenge is the design, analysis and implementation of a custom fully-independent suspension for the Venturi Buckeye Bullet 3 which is targeting to set an international land speed record over 400 miles per hour. Many of the considerations that went into the design and analysis will be presented. The second challenge addressed is the development of a vehicle dynamics model of the land speed vehicle. There is a significant emphasis on the development of the models and obtaining the necessary vehicle parameters required to build a vehicle dynamics model. The model is developed to begin to quantify the vehicle performance, handling and stability. In the end an analysis of the vehicle stability in crosswinds is considered. The results of the work will be used to validate the vehicles performance and identify any areas of improvement. ii 3Dedication This document is dedicated to my family for their patience, support and encouragement. iii 4Acknowledgments I would like to first thank the Buckeye Bullet Electric Land Speed Racing Team members for their dedication, passion and tireless efforts. These vehicles and world records would not be possible without the countless hours, late nights and passion of the team. In addition, I would like to thank my family and girlfriend for their continual support through my education and involvement with the Buckeye Bullet. Their unwavering support and encouragement has allowed me to accomplish the challenges that have been presented to me. The Venturi Buckeye Bullet 3 would also not be possible without several key important sponsors. The support from Venturi Automobiles, A123 Systems, The Timken Company, Cooper Tire & Rubber Company and MathWortks along with many more sponsors have made this project possible. All the partners have contributed to my education and development to make me a better engineer. Finally I would like to thank Giorgio Rizzoni for your support of my research. I would especially like to thank Jeff Chrstos for his continual support and advice through every step of the development of the vehicle as well as my research work. iv 5Vita January 8, 1989 ..............................................Born – Dayton, OH 2007 ...............................................................Graduate, Thomas Worthington HS 2007-2013 .....................................................B.S. Mechanical Engineering, The Ohio State University 2007-2013 ......................................................Buckeye Bullet Team Member 2013-2015 ......................................................Buckeye Bullet Mechanical Team Leader 2013-Present .................................................Graduate Research Associate, Center for Automotive Research, The Ohio State University 2015-Present ..................................................Buckeye Bullet Team Leader 6Fields of Study Major Field: Mechanical Engineering v Table of Contents Abstract ............................................................................................................................... ii Acknowledgments.............................................................................................................. iv Vita ...................................................................................................................................... v List of Figures ..................................................................................................................... x List of Tables ................................................................................................................... xiv Nomenclature .................................................................................................................... xv Chapter 1: Introduction ...................................................................................................... 1 1.1. Land Speed Racing................................................................................................... 1 1.2. History of the Buckeye Bullet Program ................................................................... 5 1.2.2. Buckeye Bullet 1 (BB1) .................................................................................... 6 1.2.3. Buckeye Bullet 2 (BB2) .................................................................................... 7 1.2.4. Venturi Buckeye Bullet 2.5 (VBB2.5) .............................................................. 8 1.2.5. Venturi Buckeye Bullet 3 (VBB3) .................................................................... 9 1.3. Research Motivation and Organization .................................................................. 12 vi Chapter 2: Background .................................................................................................... 14 2.1. History of Buckeye Bullet Suspension Designs ..................................................... 14 2.1.1. Buckeye Bullet 1 ......................................................................................... 14 2.1.2. Buckeye Bullet 2 ......................................................................................... 16 2.2. History of Buckeye Bullet Vehicle Dynamics Analysis ........................................ 18 2.2.2. Buckeye Bullet 2 ............................................................................................. 20 Chapter 3: Venturi Buckeye Bullet 3 Suspension Design ............................................... 21 3.1. Kinematics .............................................................................................................. 21 3.1.1. Buckeye Bullet 1 ......................................................................................... 21 3.1.2. Buckeye Bullet 2 ......................................................................................... 22 3.1.3. Venturi Buckeye Bullet 3............................................................................ 22 3.2. Wheel Hub.............................................................................................................. 26 3.2.1. Buckeye Bullet 1 ............................................................................................. 26 3.2.2. Buckeye Bullet 2 ............................................................................................. 28 3.2.3. Venturi Buckeye Bullet 3 ................................................................................ 30 3.2.3.1. Spindle ..................................................................................................... 31 3.2.3.2. Bearings ................................................................................................... 34 3.2.3.3. Bearing Setting......................................................................................... 37 3.2.3.4. Seals ......................................................................................................... 38 3.2.3.5. Housing .................................................................................................... 40 3.2.3.6. Analysis.................................................................................................... 42 3.3. A-Arms ................................................................................................................... 43 3.3.1. Buckeye Bullet 1 ............................................................................................. 43 3.3.2. Buckeye Bullet 2 ............................................................................................. 44 3.3.3. Venturi Buckeye Bullet 3 ................................................................................ 46 3.3.3.1. Upper A-Arm ........................................................................................... 46 3.3.3.2. Lower A-Arm........................................................................................... 48 3.3.3.3. Analysis.................................................................................................... 49 3.4. Wheels .................................................................................................................... 53 3.4.1. Buckeye Bullet 1 ......................................................................................... 53 vii 3.4.2. Buckeye Bullet 2 ......................................................................................... 54 3.4.3. Venturi Buckeye Bullet 3............................................................................ 56 3.4.4. Analysis......................................................................................................
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