Student Car Research Articles

Application of Finite Element Algorithms for Formula Racing Steering Wheels

The steering wheel of a Formula Student car has an important influence on the driving and handling stability of the car. The steering wheel of the racing car must have good mechanical and stable performance, taking into account lightweight and economic performance. Due to the small riding space of the car, the size of the steering wheel is not required to be too large. In this case, it is very difficult to meet its harsh stress state and control its vibration and noise. Based on the general requirements of the competition rules of the Formula Student racing competition, this paper constructs the geometric model of the steering wheel of the racing car by using the computer 3D design software CATIA. ANSYS software was used to conduct finite element analysis of the mechanical properties of the metal skeleton of the steering disc. Magnesium alloy, a light material with excellent mechanical properties, was selected, and combined with the actual working conditions of the steering disc, especially the force under extreme conditions, the computer simulation results showed that the force distribution and displacement of the steering disc met the design requirements. Considering that the noise and vibration of the steering wheel will have a great impact on the racer, the modal analysis of the steering wheel is carried out by using ANSYS software, and the analysis results show that there is no resonance or instability.

Formula Student car chassis – research on the torsional stiffness

In the article, the torsional stiffness of a formula student's space frame was analyzed. The article mainly focuses on the comparison of the stiffness between different frame designs, which were used in three consecutive formula student cars designed by the weracing™ team as well as a comparison of the result of two calculation methods. The calculations were made in computer-aided engineering software, i.e. ABAQUS dedicated to analyzing Finite Elements models. The assumption for analysis was to check the rotation of the frame after applying a 5000 Nm load. The torsional load was introduced by first fixed the four rear bulkhead joint and then subsequently applying a force couple to the upper front wishbone mounts. Having a distance between joint from the central line and torque moment, the force for specific nodes can be calculated. The calculation for each model was performed. The obtained differences result from the construction of frames and applied methods of calculations.

Modeling and Tuning of Electronic Throttle Control System in Formula Student Car

The Lookprabida formula student team uses an electronic throttle control (ETC) system in the racecar. Unfortunately, the ETC system cannot regulate the throttle valve to closely pursue angular setpoints. Thus, this paper endeavors to improve the response of the ETC system in racing cars. The ETC system is first examined using frequency response analysis. Parameter identification is carried out to obtain a mathematical model for the electronic throttle body. The Ziegler-Nichols’ second method is then applied to preliminarily select the proportional integral derivative (PID) gains using MATLAB/Simulink®. Then, the ETC system fine-tuning on the experimental set is carried out. The final PID controller design results in a reduction in the settling time from 0.35 to 0.20 s, overshoot from 29.6 to 19.33%, and steady-state error from 2.00 to 0.22%. The racecar with the finally designed PID gains is tested on a training track; the root mean square error (RMSE) shows that the throttle valve approaches much closer to angular setpoints.

Enhancing formula student car performance: Nose shape optimization via adjoint method

For a formula student vehicle, the nose is the first point of flow contact and decides the flow direction to help other aero components work efficiently. Therefore, an optimized nose shape is crucial for the optimum running condition of the vehicle. In recent years, Gradient-based optimization in the automotive industry has emerged with an adjoint approach. The adjoint solver is used to modify the geometry such as the nose of a car to the best optimal shape with respect to other design variables. Hence, the present study encompasses an examination conducted under six distinct Reynolds number conditions, specifically, 8.15 × 105, 9.05 × 105, 9.96 × 105, 10.87 × 105, 11.77 × 105, and 12.68 × 105. The simulation setup is validated using the Ahmed Body's 30° slant angle. The setup uses the k-omega SST turbulence model to capture the airflow phenomenon over the racing car. The simulation setup shows only a 0.07 % variation from the existing experimental findings. The results are represented in terms of different 2D plots, contours and streamline plots. The optimized nose has 27 % less drag and consumes 27.09 % less fuel than the base model at a Reynolds number of 10.8 × 105. To the automotive industry and race community, this optimization technique will be expected to enhance the vehicle's overall performance.

Lightweight Design and Analysis of Steering Knuckle of Formula Student Car Using Topology Optimization Method

The steering knuckle is a crucial component of student racing vehicles, designed by the Formula Society of Automotive Engineers (FSAE). Developing a lightweight (LW) vehicle that meets the requirements of the student formula car presents a challenge. This study presents a LW design of the steering knuckle using the Topology Optimization (TO) approach for the Formula Society of Automotive Engineers (FSAE) competition considering two different mass constraints (40% and 48%). Moreover, the research includes Stress–Life (SN) curves for three materials, structural steel, 4130 steel, and AISI 1020 steel, providing essential insights into the fatigue characteristics of the model. The results compare the three materials and two mass reduction levels, with steel 4130 achieving a significant mass reduction of 42.70%. Additionally, steel 4130 exhibits superior performance in weight reduction, stress, deformation, and safety aspects. The optimized design meets the criteria for strength, stiffness, and safety under various conditions. The fatigue analysis reveals that AISI 1020 and steel 4130 have superior endurance (1 × 105 and 2 × 105 cycles, respectively). This research provides significant contributions to the development of a LW, high-performance steering knuckle for student formula racing vehicles, highlighting the significance of TO and material selection in achieving optimal outcomes.

Design and Analysis of Fixed Brake Caliper using Additive Manufacturing

Abstract: The brake caliper's function is to channel the mechanical force generated by the driver's mechanical action on the brake master cylinder—pressurized fluid—into an outward force that may be directed to the car's brake rotors. The effectiveness of the brakes plays a significant role in a vehicle's performance, and the design of the caliper may be improved by taking into account elements like the bleeding port, the brake pads, and the fluid flow path. As two-wheeler calipers are often used in automobiles, the entire system must be dismantled, bled, and then reassembled involved halves. Custom calipers have been employed by commercial automakers to cut back on the extra work involved in developing and producing RH and LH calipers. This project aims of this project are to create, evaluate, and maybe construct a front brake caliper prototype for the Formula Student cars. The desired outcome would be for the brake caliper to outperform all of the "firms" and set us apart from the other competing teams. Additive manufacturing is a new and rapidly developing manufacturing method. The current manufacturing processes for brake calipers separate components assembler.

3D numerical analysis of the structural behaviour of a carbon fibre reinforced polymer drive shaft

Due to their high strength and favourable mechanical behaviour, metals are used in a variety of applications within the automotive industry, including drive shafts. However, the use of metallic drive shafts in the automotive sector presents some disadvantages such as high inertial masses. This work investigates the mechanical benefits of using Carbon Fibre Reinforced Polymers (CFRP) for manufacturing drive shafts. A Formula Student car was used as a model for the present work design for the drive shaft. Drive shafts made of Steel AISI 4340, Aluminium, and CFRP are investigated when subjected to mechanical excitations. Simulation includes the use of Comsol Multiphysics software. The CFRP drive shaft was modelled using the layered material feature. Various stacking sequences are tested. Results show that [90°/0°/-45°/+45°] sequence presents the best mechanical behaviour. Analytical and numerical calculations for the natural frequencies are performed and compared. CFRP drive shaft is observed to give the highest fundamental natural frequency when compared to the metallic counterparts. Fatigue analysis are also studied and revealed that the drive shafts can sustain the applied load for its expected fatigue life, with the CFRP drive shaft having the highest fatigue usage factor. Critical buckling analysis showed that the drive shaft made of steel has the highest critical buckling torque. However, drive shafts made of carbon fibre reinforced polymer was found to be 40.7% lighter than the aluminium tube and 79.6% lighter than the steel tube.

Performance Analysis and Lightweight Design of Steering Knuckle of Formula Student Racing

In this paper, the FSC Formula car ELSA of Wuhan University of Technology in 2020 is taken as the research object. On the premise of complying with the requirements of 2021 China Formula Student Car Competition Rules, CATIA modeling software is used to complete the model establishment and overall assembly of the steering knucle. It is imported into the finite element analysis software Ansys for grid division and static analysis, analysis of the stress and strain of the steering knuckle, and based on this, the structure design of the steering knuckle. In order to meet the performance requirements of the competition, lightweight design should be carried out as far as possible.

Pipe profile optimization of formula student chassis for torsional stiffness

One of the key aspects of designing a formula student car chassis is torsional stiffness. High torsional stiffness gives stability to the suspension system and provides better handling of the car. This paper presents an investigation into the optimization of the torsional stiffness of formula student chassis’ structure using Finite Element Analysis (FEA). Three sets of pipe profiles are considered, each produced chassis with different masses, and their torsional stiffness is analyzed in ANSYS. The profiles are selected within the limit prescribed by the formula student UK rules, and round pipes are used. The chassis is designed in SOLIDWORKS and then analyzed in ANSYS for torsional stiffness. The selected chassis for analysis have masses of 32.1 Kgs, 45.0 Kgs, and 47.2 Kgs based on the pipe sizing used in each chassis. These findings have important implications for the design and optimization of formula student chassis, particularly in terms of balancing the trade-off between mass and torsional stiffness. Overall, this paper contributes to the ongoing research into the optimization of formula student chassis.

Optimization Design of Suspension and Steering System for FSAE Racing Car

The China Formula Student Car Competition has been growing in recent years. In order to improve the steering lightness and body stability of FSAE cars when driving under high-speed and multi-curve conditions. This paper constructs a three-dimensional model of suspension and steering system through CATIA according to the requirements of race rules, applies ADAMS/Car module to simulate the suspension system with two-wheel isotropic excitation, obtains the change curve of suspension performance parameters, and uses ADAMS/Insight module to optimize the unreasonable parameters through the analysis results. Based on the preliminary optimized suspension system, MATLAB is used to optimize the steering trapezoidal mechanism to make the wheel steering on both sides of the race car more closely match the ideal Ackerman geometry relationship. Finally, ANSYS is applied to finite element analysis of the important parts of the suspension and steering system to ensure that their structure and materials can meet the requirements of the whole car design.

АNALYZING OF TESTING АUTOMOBILES USING STRAIN GАUGES CONSIDERING LOCАL CONDITIONS

The given аrticle deаls with testing the validity of mаchines using strаin gаuges аs well аs the dynamic behаvior of a vehicle the forces and moments аcting on the wheels. The level of accuracy should be acceptable. Since all the tire models used in the literature calculate the tire forces and moments based on parameters which are difficult to measure or estimate online, in this paper a different approach is undertaken. A wheel rim from a formula student car was fitted with strain gauges and a study was conducted with respect to the feasibility to estimate the static load applied to it. The results of this research highlight the differences encountered and discuss possible solutions.

Design and Fabrication of Exhaust System of Formula Student Car

Abstract— The overall aim of this paper is to refine the design and manufacturing techniques of the exhaust system of FSAE cars. The main objective of this paper is selection of ideal geometry of the 4-cylinder engine (GSX R600) exhaust manifold in terms of optimization of back pressure and reduction in gross weight of the exhaust system. For achieving this, we have considered runner length and diameter, muffler diameter, flow of gases in the exhaust manifold, volumetric efficiency, etc. Softwares used in design and validation are Solid works, Ansys and GT Suite. Keywords— FSAE, Exhaust Runners, Collector, muffler, CFD, 1-D engine simulation, NRC

DESIGN AND ANALYSIS OF SPROCKET FOR FORMULA STUDENT VEHICLE

In a Formula student vehicle, the sprocket is one of the important components in the chain drive which transmits power from the engine output shaft to the drive shaft. To ensure efficient power transmission, sprocket should be designed and manufactured properly. In this study the driven sprocket of the formula student vehicle has been designed in Solid works and analysed using FEA. ANSYS software has been used to perform Static analysis to calculate the stresses induced and deformations in the sprocket. And then the Fatigue analysis has been done to determine the Fatigue life and damage. The sprocket is then optimized for weight reduction and re-analysed in ANSYS for safety and reliability. Chain sprocket is one of the most important parts used in transmitting power from the engine to the drive shafts. This study mainly deals with the design and analysis of rear sprocket of a Formula Student car. This sprocket is designed such that it is light in weight and functions efficiently. The type of chain used is roller type chain. The main challenge faced is determining the proper material and number of teeth for chain sprocket. Many iterations were carried mathematically to determine the total number of teeth and final drive ratio. The CAD model was created in SolidWorks and Finite Element Analysis was carried out in ANSYS Static Structural module. Initially a solid sprocket was created without any slots for different materials and Static structural analysis was performed. For doing static analysis, the forces and torques acting on the teeth of sprocket were calculated. Boundary conditions

Analysis of the Performance and Overall Efficiency of a Formula Student Electric Car

In this paper, the performance and overall efficiency optimization process for a full-electric Formula Student car are reported. The Formula Student Electric is a scientific-educational competition of high technological value that requires the development and construction of a fully electric open-wheel prototype car; the cars rival both in terms of absolute performance and in terms of total energy efficiency, especially in the most important test, the endurance event. The optimization of the performance and efficiency of the cars affects various aspects of both the powertrain and the car body and, as macro areas, three crucial themes can be identified for the development of the cars: the power maps with which the inverter manages the electric motor, the aerodynamic kit installed onboard and the overall weight of the car. In this regard, in fact, it is not obvious, for example, that it is convenient to use the maximum power allowed by the rules for the powertrain (80 kW); in the same way, it is not inevitable that it is advantageous to install all the components of the aerodynamic kit (front wing, rear wing and undertray with diffusers) and, finally, the best configuration may not be the one with the lightest car. This is also in consideration of the fact that some choices must necessarily be a compromise, such as completeness of the aerodynamic kit and vehicle weight. Hence the search for an optimum point is necessary. The work proposed here aims to describe the experimental search for the optimal configuration for the car of the Sapienza Fast Charge team. To achieve the goal, the analysis has been conducted with several experimental tests on a simple test ring with a dynamic configuration comparable to that of a typical endurance track. The tests have been fulfilled with different combinations of aero-kit configurations, with the aero devices available on the car, rear wing, front wing and undertray, and with different energy management strategies, implemented in the power map of the inverter. The best result has been achieved considering the official ranking calculation of the Formula Student rules 2020, with a combination of best track time and lower energy consumption. The work described here will start with the description of the prototype vehicle, reporting the details of the powertrain and storage system installed onboard. Then, the aerodynamic devices designed and built will be described, and the CFD analysis of their performances will also be reported. In the following, the description of the test track will be discussed and a comparison of a typical track of an Endurance test in Formula Student will be fulfilled. Finally, the parameters measured experimentally will be described and all the tests carried out will be discussed, in order to determine the optimal configuration of the car.

Experimental measurement of cooler pressure loss of Formula student car

To achieve the maximum performance of an engine while maintain safety of the race car, it is essential to cool it properly. Therefore, this article deals with the experimental measurement of the cooling modules pressure drop of the formula student car. Leading to the right choice of the fan behind the radiator. Series of measurements were taken at the UWB in the wind tunnel of the department of Power System Engineering.

Multi-objective optimization of centre locking hub bolt of automobile wheel under conflicting objectives

The need for quick detachment and replacement of tires in the motorsports and Formula racing industry is achieved by the use of Central Locking (CL) hub bolt. The present work implements the concept of CL hub bolt for Formula Student Car where the use the conventional 4-bolt wheel hubs is more prevalent among many student teams. This modification leads to a simplified version for a Formula Student Car design in which the time for wheel assembly considerably reduces. The present work focuses on the optimization of a CL hub bolt design for Formula Student Car. The bolt design variables are constrained to satisfy two requirements which are conflicting: first, to minimize weight by maintaining stresses within the limits governed by different materials and second, to restrict bending deflection of the bolt. This situation demands use of the multi-objective optimization techniques. The bounded objective function method and utility function method based on stochastic random search are used for optimizing the design variables and to achieve the best balance between the values of weight and deflection. The results from two methods are presented in the form of variation in weight and deflection against the bounds and weighting factor respectively for bounded objective function method and utility function method. The selection of parameters like bounds and weighting factor is observed to be an important criterion in multi-objective optimization. An approach to help in the selection process is established based on several iterations. The developed approach allows users to fine-tune the results to achieve the desired values within the set constraints.

Finding optimum Ackermann geometry for a car undergoing steady state cornering using tire data

For a car to have minimum lap times across a track it should be able to produce the maximum cornering force or side force in order to complete the corner at the maximum velocity possible. The grip level of a particular tire limits the maximum side/lateral force it can produce. To find the best steering geometry for a car one should know the grip limit of the tire and at which slip angle it is being produced. This paper provides a simple methodology to find the appropriate Ackermann steering geometry, which can produce the maximum lateral tire grip going through different high speed constant radius corners. Hence, reducing the time spent on-track while testing to find out the suitable steering setup and improving the overall cornering ability of the car. The raw tire data from tire testing runs of the tire: Hoosier 18.0 X 6.0 – 10 R25b is used to fit curves to the raw data using two tire models based on the Magic Formula and Data Non-dimensionalization methods respectively. The results from both of the methods are compared. These tire models are then used to find the ideal steer angles of the front tires at various constant radius steady-state turns and thus the Ackermann geometry of a Formula Student car producing the maximum possible grip.

Power Train Designing for Formula styled Racing Car

Abstract: A wheel assembly is an integral part of a vehicle’s design that connects the wheel to the suspension system and transfers pressure from the road to the suspension system. It also holds the brake system and facilitates steering. Power transmission is also addressed in the powertrain department. We describe the process and simulation that result in the hub, upright, and differential mounting of a formula student car and the size of the sprocket for maximum acceleration in this report. As a result of the work done on this project, the resulting car has improved acceleration, is easy and reliable to assemble, and has fewer breakdowns than the previous model. The report includes all the calculations that support the simulations and a validating statement about the bearing selection.

Conceptual Design of Modular Chassis Jig of Student Competition Car

Chassis jig is needed to ensure that the welded chassis components does not warp or deform during welding process. Through concept screening and concept scoring, multiple design of chassis jigs is narrowed down to next development process. This study aims to design a chassis jig for the fabrication of student car competition chassis. The desired result of this design process is chassis jig with the ability to manufacture a wide variety of student competition car chassis.

The Theoretical Study of an Interconnected Suspension System for a Formula Student Car

When it comes to racing applications, the primary engineering goal is to increase the performance envelope of the vehicle for a given set of tires. To achieve this goal, it is necessary to maximize the normal loads on the wheels while at the same time minimizing the tire load variation. The purpose of this paper is to present a mathematical model for a Formula Student car in order to study if performance gains are achieved by replacing the traditional passive suspension with a hydraulically interconnected suspension system. To have a complete picture of the advantages and disadvantages of each system, two vibrating models with 7 degrees of freedom were created in order to simulate the motion response of a Formula Student car to realistic excitations. Two particular interpretations of the results were chosen as important performance indicators. The first one is given by the pitch stability of the chassis relative to the road, which can be linked with a decrease in downforce load variation. The second one is the ability of the wheel to follow the road profile as closely as possible, which can be directly correlated with the amount of mechanical grip of the vehicle. The simulation results indicate that the hydraulically interconnected suspension system offers better results for both proposed cases but at the expense of the roll stability of the vehicle.