FSAE Suspension

ME 191 Final Presentation

Spring 2009

Team Members:
Jarret Vian
Bryan Rowley
John Murray
 Outline
Introduction
Re-Design
Manufacturing
Testing
Conclusion
Introduction
 Design

Requirements
Minimum 60 wheel base
Unequal front & rear track widths
Minimum 1 ground clearance
Minimum 2 total suspension travel
Template must pass through frame
Spherical bearings must be in double shear
Design must handle applied loading

Design Goal
Rate of camber angle change with respect to
both body roll and wheel displacement
 Re-Design
Original Final Design
Manufacturing
Manufactured at CSUS, by FSAE team
Manufacturing
A - Arms
 Bearing Holder

Hub & Spindle

Upright
Geometry Testing

Camber Wheelbase
Caster Track Width
 Goals
Rate of camber angle change per degree
body roll

Camber Angle vs. Body Roll (Theoretical) Camber Angle vs. Body Roll (Experimental)
3.50 1.00
3.00
f(x) = 0.75x - 0.56 0.50
2.50 f(x) = 0.79x - 1.51
R = 1
2.00 0.00 R = 1
1.50
-0.50 Camber
1.00 Camber
Camber Angle (Degrees) Linear (Camber)
Camber Angle (Degrees) Linear (Camber)
0.50 -1.00
0.00
-1.50
-0.50
-1.00 -2.00
5.00
0.00

Body Roll (Degrees)

Body Roll (Degrees)
 Rate of camber angle change per inch of
wheel displacement

Camber Angle vs. Wheel Displacement (Theoretical) Camber Angle vs. Wheel Displacement (Experimental)
1.00 0.00

0.50 -0.50
f(x) = - 0.76x - 0.55
R = 1 f(x) = - 0.81x - 1.23
0.00 -1.00
R = 0.96
-0.50 Camber -1.50 Camber
Camber Angle (Degrees) Linear (Camber) Camber Angle (Degrees) Linear (Camber)
-1.00 -2.00

-1.50 -2.50

-2.00 -3.00
2.00 5.00
-2.00 -5.00

Wheel Displacement (Inches) Wheel Displacement (Inches)

Upright Testing

Strain Gages
 Strain Gage
Installation

Degrease Solder Connect to

Abrade instrumentation
Burnish
Condition
Neutralize
M-Bond 200
 Loading Scenario:
759lbs

Apply the load, and maintain a constant force on the tire

139lbs, 300lbs, 400lbs
Read the strain from each channel on the instrumentation
Strain Stress
 Stress Extrapolation
Rosette 1
3,000

2,500
f(x) = 5.98x
2,000 R = 1

1,500
Von Mises Stress (psi)
1,000

500

0
100 150 200 250 300 350 400 450

Load (lbs)

Elastic
 FEA Stress Value

Rosette location Probe

 Theoretical
Experimental

Sy = 50,800psi

Assumption: rigid Assumption: smooth

 Future Testing Plans
Straingauge and accelerometer data logged
during driving

Mychron 3 data logger Strain gauges

with internal Accelerometer
Conclusions
 Budget
PREDICTED COST ACTUAL COST

MATERIALS 1545 610

BEARINGS 246 130

HARDWARE 232 135

TOTAL 2023 875

 Lessons Learned

Engineering is challenging and rewarding

Never underestimate the scope of a project

Always test to verify assumptions

Questions