composite suspension for formula sae vehicle

8/18/2019 Composite Suspension for Formula SAE Vehicle

1/62

1

Composite Suspension for Formula SAE Vehicle

A Senior Project

presented to

the Faculty of the Mechanical Engineering Department

California Polytechnic State University, San Luis Obispo

In Partial Fulfillment

of the Requirements for the Degree

Bachelor of Science in Mechanical Engineering

by

Reid Olsen

Andrew Bookholt

Eric Melchiori

June, 2010

© 2010 Reid Olsen, Andrew Bookholt, Eric Melchiori


2/62

2

1. I ...................................................................................................................................... 4

2. P S ........................................................................................................................... 4

3. B ..................................... .................................................................................................. 5

3.1 M........................................................................................................................... 5

3.2 B MC J .......................................................................................... 6

3.3 D A S ......................................................................... ................................. 7

4. O.......................................................................................................................................... 9

5. D C .............................................................................................................................. 10

5.1 I G D M B ................................................................. 10

5.2 T A ........................................................................................................................ 11

5.3 A A J ........................................................................... ................................ 12

6. D P D................................................................................................... 14

6.1 A ........................................................................................... .......................................... 15

6.2 TF M ............................................................................................................... 17

7. C ................................................................................................................................................. 18

8. P R ......................................................................................................................... 18

8.1 A ........................................................................................... .......................................... 18

8.2 TF M ............................................................................................................... 22

8.3 S G I ......................................................................... .................................. 23

9. T D ...................................................................................................... 24

9.1 D T ................................................................................................................. 24

9.2 ND T .......................................................................... ............................... 26

10. C ................................................................................................................................... 29


3/62

3

A .............................................................................................................................................. 32

A A. ......................................................................................... 32

A B. .................................................................................... 33

A C. ................................................................. 34

A D. .............................................................................................. 35

A E. .............................................................................................. 36

A F. ............................................................................................................... 37

A G. ................................................................................................................... 38

A H. ......................................................................................................... 39

A I. ................................................... 40

A J. ............................................................................................. 41

A K. ............................................................................... 42

A K. ................................................................................................................. 44

T C D .......................................................................................................... 44


4/62

4

1.

T C P S F S A E (FSAE)

2008

. T

A, / , . T

FSAE . T R O, E M A

B C S S .

2.

S , , ,

. D F SAE , ,

. T

, 90% . T

. T

,

.

,

.

P, A

. C

. A,

.

1: B


5/62

5

I ,

. T

. T

. A ,

. F 1

.

C S S FSAE

. T

A, . T

.

D

.

3.

3.1

T

. C

. E

. T

,

,

. T

F 2 . C

.

2:


6/62

6

T

. T . T

. I

. H,

,

. T

.

A 100% . E

. P

. T ( )

. T

. T,

.

C . A,

K, . H,

. T,

K . T F 2: R C

T , K .

3.2

T . T

,

, . F ,

, ,

. T

.

T . D

,

. T

. T

.


7/62

7

T

.

,

. T

O F P L (FPL) E. T FPL

E . T

. T FPL

,

. T ,

.

A P A A . D B 1975,

PAA 10 FPL .

T ,

. T PAA

FPL . A

.

T , ,

S 860 A

E ( F 3.) T

,

.

B . O

, . I

.

FSAE

.

3.3

B ,

. T

3: ' A


8/62

8

. S

I M (IM) M . T

.

.

I ,

. A,

(.375)

. MM ,

($1/).

A

A H.

P 125 1390 μ. T

, .

350Ω

. T ,

. T

. I

.

, IM

. S ,

. S

. L

,

EMI . T IM

1000 H. T 15 . I 3 ,

.00018 /.

4:


9/62

9

4.

T C P FSAE

. A ,

, ,

. T

. B

, .

, . T

, A .

. I ,

; , , ,

. H, .

T Q F D (A A. )

. F QFD ,

, , . S

.

. T QFD .

S

. T

. C,

, 4%, 6%,

2%, , QFD .

E ,

FSAE . T (A )

F E A , ,

. T (T )

. F ,

(S ) .


10/62

10

1:

R T R C

1.

S 1.5 S F+10%

0%H A,T

2. 20%

+N/A

10%H A,T,S

3. S 10% I+10%

0%H A,T,S

4. M N/A N/A M T

5.

C 20% +10 %

N/AL S

6.

A N/A N/A L I

T (T 1) QFD. E

( ) . F

,

. T . H,

, . I

, . T,

.

M, , .

M C S S

F SAE . C ,

.

5.

5.1

D ,

. T

, . S

.


11/62

11

S . E

, . T

. S

FSAE , . T

,

. E

, . C

SAE

. A

, .

5.2

5.2.1

C, . T

. A,

FSAE . H,

C P FSAE

.

5.2.2

A

.

. H, , . T

, , .

F,

.

5.2.3

A 95 %

. T 5%

. T

.


12/62

12

5.2.4

C

, , . L

. C

. R

. A, ,

.

2:

R C M

R

C M

A P

F

R

RR

R

R

R

5 1 5 1 5 1 5

3 0 0 1 3 1 3

4 1 4 1 4 1 4

5 1 5 1 5 1 5

A 1 1 1 1 1 1 1

2 1 2 1 2 1 2

9 4 0

5.3

5.3.1

O A

. I

. E

F 5. T

. T

. 5:


13/62

13

5.3.2

T

. T

CNC A

F 6. I ,

. T

. A,

, . T

. T

. I , .

5.3.3

C . H, F SAE

. T

CNC . T

.

5.3.4

3:

CNC A C A C JP D

( )

4 0 0 1 4 1 4 0 0

2 0 0 1 2 1 2 0 0 4 1 4 0 0 1 4 0 0

5 1 5 1 5 1 5 0 0

A 1 0 0 1 1 1 1 0 0

2 1 2 1 2 1 2 0 0

11 10 10 0

6: A


14/62

14

C

. C

. C ,

, , . CNC

.

6.

T , .

A C. . T

4.9 . T, 20%,

.4 . T

50%. A ,

.

T CAD A

. T

. T

. H,

.

T A CNC . A

. T

, . I

, , . P

. B

.

A CNC . A

C P FSAE ,

. A

A .06

. T .25


15/62

15

. T A E.

.

T P/E M. I F E A

P/E. I FE . M

FEA ABAQS CAE. E

. A

. T

. T

. T

.

6.1

6.1.1

T . T,

. B CNC ,

. H,

CNC

. T,

P/E M FEA

, . A H.

,

.

7: A


16/62

16

T A H.

A P/E

M. T

410

135

. T

24.5 76

7075T6

. I ,

. H, . A C.

A.

H, FEA . T

1500 . T

. T

3000 . T

6.8. A,

.

6.1.2

T A

A .

E 1800

880 . T

1100 .

A

A , . T,

.

A

8: A A

9: A


17/62

17

.

T A

. N

A

. I

. T

FEA

F 10. T

8400

76 7075 T6 .

A , A

. O , 1500

. T 3500 . T

2. H, ,

.

6.2

T

. T

. T

. F ,

. T 1100

1.13. T 120

1.38. B .

11: / A

10: A A


18/62

18

7.

T . I , $120

$150 . , ,

F SAE . T , 7075T6 ,

. I C S S ,

.

T F SAE

SAE . T

.

8.

T

C P F SAE . T

. T

. T

. C

.

8.1

8.1.1

T

. F

,

. T

F SAE 2 4

,

. T

12:


19/62

19

. O 3

.

B

.

,

. T

F 12. A , 3

. I

.

F , 3/8

. I ,

. T 3D

( .003.)

T . I

,

. T

.100

. T

3

. T

.

T

.

13:

14:


20/62

20

, , .

T . T

, 123 . 123

123. T . O

90

. T 3 . F 14

.

T 270 . A

. T

. S

.

8.1.2

T A

, ,

. I

,

,

CNC .

T

. E

CNC

.001.

H,

,

.

,

. T,

15:


21/62

21

. T

.

T

C. T

C

.

T

. A 2D

. T . O ,

90 . N

90 . A

C .

8.1.3

O

. F , . T

, .

R .

T

. F,

,

. T

.

O

16: B B A

17: B A A


22/62

22

.

T . T

. T

. L , .

T A . I

. T A

. N,

. T . T

. T

. T 12 .

8.2

B

,

. T

. T

A . T

.

T . T

18: B


23/62

23

. H,

. T

.100 . T

. T

. T 12 .

8.3

S

. T

. A,

.

, . A

. T

,

. A ,

. T ,

. T

. A . A

, , . A

,

. A , , .

T ,

. A , . T

.

T

. ,

(+), (), (A), (B), . T 35 DC

+ . T ,

. T A B


24/62

24

.

9.

T . I

. E ,

, . S

20% . E

. F ,

.

T . T,

. I ,

. T

.

9.1

.1.1

T ASTM D905. T

DP110

, . T

. T

. T

I . T

.002 /,

. T /

F 19.


25/62

25

19: B /A .

F , 4476 . A ,

2.8 2. D

. T 1592 /2. T

DP110 2000 /2,

. A ,

, S 860

A E .

.

0

1000

2000

3000

4000

5000

6000

3.85 3.90 3.95 4.00 4.05

T e n s i l e L o

a d

( l b )

Head Displacement (in)


26/62

26

9.2

.2.1

C . I

, . J

. F ,

. F

20 A

I F

T.

A

I

. T

I . T

20,000

. O

. T

. F

,

. T .

20: A


27/62

27

C F SAE ,

. A ,

. T,

. T I

.

A A I.

I I A . H,

I

. T,

. A 28 A

. T A

I .

A T 4 , . T ,

. T

. T

A .

4:

A

()

F A 410 P N/A

R A 135 P N/A

F L A 1800 P N/A

R L A 880 P N/A

.2.2

. A ,

I . T

. E

,

.


28/62

28

T

. H, FSAE 2008 ,

. T,

. C

I

. T .

.2.3

M

. S

. T

/

.

,

. B ,

. T , 6 ( )

. T

DAQ, . A

, . T

,

( F 21) , /. T

.


29/62

29

21: .

.2.4

S , ,

. A ,

. T

. T

, . A ,

. I ,

. A,

,

.

10.

A , C S S

. I, C P F SAE

. H,

2008 . O

.

0

5

10

15

20

25

30

35

40

45

0 100 200 300 400 500

F o r c e

( l b )

∆V (mV)


30/62

30

T,

.

A ,

. T . D ,

40% . T

F SAE . A

.

, ,

.

. T $500. A

. H, SAE

, . T

.

T . T

.

. H,

.

T CNC . E

.

D , C S

S 2010 F SAE

. A QFD A A. , ,

. C

. T

.


31/62

31

R C S S ,

, . T 2008

A / .

.

A

.

. T CNC ,

, . A ,

.


32/62

32

.


33/62

33

. ( )

P E S

R L T

A* .643 .641 1.550L A* 1.403 1.407 2.810

P .31 .31 .62

T

4.98

*D ,

.

T,

A .


34/62

34

. ( )

P E S

R L T

A .378 .378 .756

L A .618 .622 1.40

P .130 .131 .261T

2.417


35/62

35

.

R C M

R

C M

A P

FR

RR

RR

R

5 1 5 1 5 1 5

3 0 0 1 3 1 3 4 1 4 1 4 1 4

5 1 5 1 5 1 5

A 1 1 1 1 1 1 1

2 1 2 1 2 1 2

9 4 0


36/62

36

.

CNC A C A C JP D

( )

4 0 0 1 4 1 4 0 0

2 0 0 1 2 1 2 0 0

4 1 4 0 0 1 4 0 0

5 1 5 1 5 1 5 0 0

A 1 0 0 1 1 1 1 0 0

2 1 2 1 2 1 2 0 0

11 10 10 0


37/62

37

.

T . F .

T . H, . F , 204

FSAE .

ITEM NO. PART NUMBER DESCRIPTION QTY.

1 103 Bearing Cup, Front A-arm Upper 1

2 101 Front Tube, Front A-arm, Upper 1

3 102 Rear Tube, Front A-arm, Upper 1

4 104 Rear Insert, Front A-arm, Upper 2

5 203 Bearing Cup, Front A-arm, Lower 1

6 201 Front Tube, Front A-arm, Lower 1

7 202 Rear Tube, Front A-arm, Lower 1

8 204 Front Insert, Front A-arm, Upper 2

9 301 Tube, Pullrod 1

10 302 Insert (RHT), Pullrod 1

11 303 Insert (LHT), Pullrod 1

12 401 Tube, Steering Arm 1

13 402 Insert (RHT), Steering Arm 1

14 403 Insert (LHT), Steering Arm 1

15 60685K721 1/4 inch Rod End 4


38/62

38

.

*A ACPC.

B*

TR07A (.500 I D .030 T 60 L)

Q 1

T C $23.75

TR08A (.555 I D .033 T 58 L)

Q 1

T C $27.50

TR08 (.555 I D .033 T 28.5 L)

Q

1

T C $15.50

TR10A (.625 I D .043 T 70 L)

Q 1

T C 42.50

T C T C (I S&H) $119.36


39/62

39

.

T S R

S M L () OD SF F M

F A 410 0.5 0.03 5.583

R A 135 0.5 0.03 10.525

P 1100 0.55 0.033 1.133

F L A 1800 0.625 0.033 1.1396 B

R L A 880 0.5 0.03 1.05

T R 120 0.55 0.033 1.38 B


40/62

40

.

Carbon Roll Wrapped Tubes

T S () 275

T M (M) 20

C S () 132

C M (M) 14.5

T S (M) 15

T M (M) 1.3

F S (109) 90

C T E

(//F) (106).24 A

D (/3) 1.52


41/62

41

.


42/62

42

.


43/62

43


44/62

44

.

E BOM . T

.

1. F A A 43

.

F

.

R

. J

.

F I

2. F L A A 48

. F

. R

. J

. F I

3.

P 53

.

T

.

RHT I

. LHT I

4. S A 57

. T

. RHT I

. LHT I


45/62

45


46/62

46


47/62

47


48/62

48


49/62


50/62

50


51/62

51


52/62

52


53/62

53


54/62

54


55/62

55


56/62

56


57/62

57


58/62

58


59/62

59


60/62

60


61/62

61


62/62

composite suspension for formula sae vehicle

Documents