FSAE Racing Suspension System Design, Manufacture And Testing

Taken the FSAE (Formula SAE) series competitions as the background, Based on the foundation and accumulated experience of FSAE car suspension system of kunming university of science and technology in 2013. The design, manufacture and test of FSAE car suspension system of kunming university of science and technology in 2014 was studied. The main research works were as follows:1. According to the rules of FSAE competitions, the designing schemes of FSAE car suspension was compared and researched. The unequal length double wishbone independent suspension was chosen as the suspension form for FSAE car in 2014. Then, the vertical plane layout scheme, horizontal layout scheme and the length ratio of upper control arm and lower control arm of suspension was determined. Based on the determined type and parameters of tire and rim of racing car, parameters of suspension were designed. Finally, parts of suspension were designed and assembled.2. Front suspension and rear suspension of FSAE car were modeled by using ADMAS/Car in ADMAS software. According to the rules of FSAE competitions, the parallel wheel travel was employed to conduct simulation analysis of suspension. The simulation parameters include wheel kingpin caster angle, wheel kingpin inclination angle, camber angle, toe angle, the wheel track width and the roll center height.3. ADMAS/Insight of ADMAS software was employed to test the front suspension and rear suspension of FSAE car by setting parametric variable and design objective. According to each hart point coordinates effect on simulated parameters, the parametric variable was optimized. Then the variation curves of design objective of front and rear suspension, before and after optimization, was obtained. The results show that the performance of front and rear suspensions was promoted integrally. It is suggest that optimization of parametric variable is valid.4. Force analysis of parts of FSAE car suspension system was carried out at urgent acceleration and sharp deceleration conditions and high speed cornering condition. Finite element analysis was conducted by ANSYS software. The results of stress nephogram and deformation nephogram of parts indicated that stress and deformation of each part meet design requirements.5. Tools which used in machining were set in Mastercam software. Then parts of suspension was processed virtually. Machining interference problem in simulation process was optimized. The processing technic and methods of parts of FSAE car suspension system, such as column, wheel core, control arm and so on, were stated particularly. Parts of suspension were assembled and interference inspection was conducted.6. The wheel alignment parameters were adjusted in FASE car suspension system test. Adjustment method, boundedness of adjustment method and matters need attention were introduced. In urgent acceleration and sharp deceleration and high speed around the pile test, linear displacement sensor installed in the damper was employed to collect the compression variation data of the damper and surface wear analysis of wheel. The damping of the damper and wheel alignment parameter were adjusted. Lateral acceleration stability and continuous lateral acceleration level of car for 2014 were advanced remarkably comparison to the car for 2013 in "8" around test.The research result in this paper was applied to FSAE car of Kunming University of Science and Technology in 2014. The car had taken part in the 2014 formula SAE of China. The car completed all items of security detection, static game and dynamic game successfully. It is proved the reliability and security of FSAE car suspension system. The summarized method and experience can provide a reference for design, manufacture and test of FSAE car suspension system.