Design and Analysis of Wheel Assembly For FSAE F3 Vehicle
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Editor IJTSRDDesign and Analysis of Wheel Assembly For FSAE F3 Vehicle
Uploaded by
Editor IJTSRDInternational Journal of Trend in Scientific Research and Development (IJTSRD)
Volume 6 Issue 4, May-June 2022 Available Online: www.ijtsrd.com e-ISSN: 2456 – 6470
Design & Analysis of Wheel Assembly for FSAE F3 Vehicle
R. G Janunkar1, Shubham Shingote2, Krushna Bankar2, Rohan Inamke2
1
Professor, 2Student,
1,2
Department of Automobile Engineering, Dhole Patil College of Engineering, Pune, Maharashtra, India
ABSTRACT How to cite this paper: R. G Janunkar |
Generally, in automotive industry, weight reduction, cost of Shubham Shingote | Krushna Bankar |
engineering design and reduction in vehicle development cycle time Rohan Inamke "Design & Analysis of
are becoming increasingly focused on. In order to tackle this, Wheel Assembly for FSAE F3 Vehicle"
Computer Aided Engineering (CAE) is popularly being used to lead Published in
International Journal
design process.
of Trend in
The aim of our project is to design, optimize and manufacture the Scientific Research
wheel assembly to compete in SAE-SUPRA competition. In this and Development
project we are going to design the wheel assembly for proper (ijtsrd), ISSN: 2456-
6470, Volume-6 | IJTSRD50120
mounting of accessories, for fast response on track, better stability
Issue-4, June 2022,
and reduction in the vibration. We are focusing on each and every
pp.755-758, URL:
point of wheel assembly to improve the performance of vehicle www.ijtsrd.com/papers/ijtsrd50120.pdf
without failure of vehicle. The major challenge is to rigidly
manufacture a light weight wheel assembly at minimal expense Copyright © 2022 by author(s) and
without compromising the driver safety. We are going to validate our International Journal of Trend in
design by using Solid works 3D cad Software. Scientific Research and Development
Journal. This is an
KEYWORDS: Formula SAE, Ansys, Hubs, Uprights Open Access article
distributed under the
terms of the Creative Commons
Attribution License (CC BY 4.0)
(http://creativecommons.org/licenses/by/4.0)
INTRODUCTION
In automotive suspension, a steering knuckle is that involves the designing of a steering knuckle with the
part which contains the wheel hub or spindle and help of designing software and by estimating the
attaches to the suspension and steering components. It loads which are acting on the component. The second
is variously called a steering knuckle, spindle, upright part is carrying out FEA on the component to find out
or hub, as well. The wheel and tire assembly attach to the stresses induced and the deformation. This will
the hub or spindle of the knuckle where the tire/wheel help in optimizing the knuckle. After the analysis is
rotates while being held in a stable plane of motion by done, the knuckle can be optimized by removal of
the knuckle/suspension assembly in the attached materials where the induced stress is low.
photograph of a double-wishbone suspension, the
Project Objectives
knuckle is shown attached to the upper control arm at
The objectives for the design and optimization of the
the top and the lower control arm at the bottom. The
SAE Vehicle Upright Assemblies are listed as
wheel assembly is shown attached to the knuckle at
followed:
its centre point. Note the arm of the knuckle that Less Weight: Compare to 2018 design.
sticks out, to which the steering mechanism attaches Maintains Stiffness: Achieve the same level of
to turn the knuckle and wheel assembly. Steering stiffness when compared to the 2016 design.
knuckle is that component of a vehicle which Maintain Serviceability/Reliability: Achieving the
connects the suspension system, braking system and same serviceability and reliability exhibited with
the steering system to the chassis of the vehicle. A the 2018 design.
steering knuckle should have high precision,
durability and low weight. The purpose of this study These goals can be verified through FEA, physical
is to design a knuckle which is low in weight and has testing, and actual on track performance of the
better performance with considerable factor of safety. vehicle. Though for the purpose of the report and due
The study is divided into two steps. The first step to the importance of the finished product, no actual
@ IJTSRD | Unique Paper ID – IJTSRD50120 | Volume – 6 | Issue – 4 | May-June 2022 Page 755
International Journal of Trend in Scientific Research and Development @ www.ijtsrd.com eISSN: 2456-6470
destructive testing will be performed on the finished An upright is one of the key components in vehicle
assemblies. dynamics which connects all suspension components
between the wheel and the car. The uprights provide a
Principle components
link between the upper and lower ball joints. The
1. Front hubs
The front hubs provides mounting holes for both upright connects components for example, the control
wheel rim and brake rotor. The rim fits with 4 holes arms, steering arms, springs, shock absorbers, brakes,
PCD 100mm and 12mm bolt diameter. A central shaft tires and at the rear it connects the axles. Since it is a
key component it must withstand all forces that the
connecting these mounting points is designed with
groves cut for inserting the roller bearings at the two suspension will encounter. The uprights must be
ends of the hub. Front Hub modelled in CATIA V5 strong enough to withstand those forces, sum may
R20, After modelling of the hub in Solid Works, the occur simultaneously for example during braking into
a corner. As for this design, the goal is to design a
model was meshed in ANSYS WB. For the impact
analysis, the central axial shaft was given a roller light, yet sufficiently strong uprights that can
support and Force of 3g was applied on the mounting withstand the forces that the new FS car will
holes of the wheel rim in upward direction. encounter.
Figure: Front hub Model Figure 4.l.1: Front upright Model
Upright
Ansys Report
Table: 5.6.l Loads on Rear Hub
Direction Magnitude Situation
Brake moment 1700Nm Braking
x 6278 N Acc/braking
y 6278 N Bump
Z 9418 N Engine torque
Torque 37Nm
Figure.5.6.1 Rear Hub Forces Analysis
@ IJTSRD | Unique Paper ID – IJTSRD50120 | Volume – 6 | Issue – 4 | May-June 2022 Page 756
International Journal of Trend in Scientific Research and Development @ www.ijtsrd.com eISSN: 2456-6470
Direction Magnitude Situation
Brake moment 1700Nm Braking
X 6278 N Acc/braking
Y 6278 N Corner
Z 9418 N Bump
Figure.5.4 1 Forces on Front Hub Analysis
Table.5.2.l load on front upright
Direction Magnitude Situation
Steering rack 1000 N Steering effort
Brake moment 1700 Nm Braking
X 6278 N Acc/braking
Y 9418 N Bump
Z 6278 N Corner
Constrain points:
Loads are applied on the A arm mounting points from all three directions and bearing seat is kept constrain or
fixed.
Solutions:
Figure: 5.2.1 Forces on Front Upright
@ IJTSRD | Unique Paper ID – IJTSRD50120 | Volume – 6 | Issue – 4 | May-June 2022 Page 757
International Journal of Trend in Scientific Research and Development @ www.ijtsrd.com eISSN: 2456-6470
Table: 5.3.l loads on rear upright
Direction Magnitude Situation
Brake moment 1700Nm Braking
X 6278 N Acc/braking
Y 6278 N Corner
Z 9418 N Bump
Figure: 5.3.1 Forces on Rear Upright
CONCLUSION References
The deflection of the upright assembly will be on the [1] Design of Upright of supra vehicle by Ashish
basis of the optimization process. With stiffness being Kumar Singh
the performance standard and weight being the [2] Design and optimization of wheel assembly of
concern. the design goals are defined to be reduction F3 car by vrushabh jijode
in weight over the 2018 design with comparable [3] Tune to Win by Carroll Smith
stiffness. To optimize for weight, sheet metal [4] Race car Engineering and Vehicle Dynamic by
thickness for different races of the upright are Milliken & Milliken
changed respectively based on the previous runs [5] Engineer to Win by Carroll Smith
stress distribution and deflection value. the material
Rule Book
thickness was reduced in the areas where stresses are
[1] Supra SAE INDIA 2019 Rulebook
in the limiting factor being stress cannot exceed the
material limit. With allowable thickness value based Reference Books
on available stock material, a number of combinations [1] V. B. Bhandari
were analysed and the optimum front and rear upright [2] Design Data
and hub designs were selected as the final designs. Internet
ACKNOWLEDGMENT [1] https://www.carid.com/articles/axle-glossary-a-
We would like to sincerely thank our guide, Prof. R. to-z-list-of-definitions.html
G. Janunkar for his helpful guidance and assistance [2] https://www.scribd.com/document/334969624/
throughout the duration of this project. Many thanks Design-and-analysis-of-hub-and-knucke-of-
also go to the Head of Department, Prof. Siddharaj FSAE-Race-Car
Allurkar for his continuous efforts for the Formula [3] https://www.scholarworks.csun.edu/bitstream/h
SAE team and his supervision over the event. Lastly, andle/10211.3/123383/Flickinger-Evan-thesis-
we would also like to thank my family and friends 2014.pdf;sequence=1
for their help and support throughout the project. [4] https://ijritcc.org/download/conferences/ICIIIM
E_2017/ICIIIME_2017_Track/1497425928_14
-06-2017.pdf
@ IJTSRD | Unique Paper ID – IJTSRD50120 | Volume – 6 | Issue – 4 | May-June 2022 Page 758
