Formula Student Design and Manufacturing
Do and Don’t Illustrated with pictures mostly taken at Student Formula Japan 2016 and 2015
Claude Rouelle
What makes me qualified to speak about race car design…. I made the same mistakes
1979 Master Thesis
What makes me qualified to speak about race car design…. I made the same mistakes
1979 Master Thesis
What makes me qualified to speak about race car design…. I made many mistakes
Race Car Engineeri Engineering ng 1980 to 1997
What makes me qualified to speak about race car design…. And I had a few success
What makes me qualified to speak about race car design…. •
Created OptimumG in 1997
•
Located in Denver, CO, USA
•
Multicultural and multidisciplinary staff Training
Simulation
Consulting
Design Judge Formula Student competitions for over 15 years Australia, Austria, Brazil, Canada, China, Germany, India, Italy, Russia, Spain, UK, USA. Several Universities course in Europe, USA, Australia and South America
Formula Student Design and Manufacturing
Do and Don’t Some basic design errors you should and can avoid Illustrated with pictures mostly taken at Student Formula Japan 2016 and 2015
Formula Student Design and Manufacturing Do and Don’t Rod end in bending If this top wishbone would break Where do you think it would break?
Right here!
Formula Student Design and Manufacturing Do and Don’t Rod end in bending What is the solution?
Linkage axis going through outboard rod end center
Formula Student Design and Manufacturing Do and Don’t Rod end in bending Linkage axis going through outboard rod end
Pull rod axis good but could have been better
Formula Student Design and Manufacturing Do and Don’t The suspension link axis must go through one node of the chassis
Suspension links through the outboard upright point
Formula Student Design and Manufacturing Do and Don’t Decreased compliances with good design
All these points should be in the same plane
Reduce compliances causes!
Formula Student Design and Manufacturing Do and Don’t Suspension links axis not through a chassis node
Formula Student Design and Manufacturing Do and Don’t Suspension links not through a chassis node
Formula Student Design and Manufacturing Do and Don’t Suspension links not through a chassis node
Determine your suspension points coordinates, then draw you frame, not the other way around ! The chassis frame is one of the last things you should draw
Formula Student Design and Manufacturing Do and Don’t Suspension links through a chassis node Coud have been shorter
Reduce compliances causes!
Formula Student Design and Manufacturing Do and Don’t Unnecessary compliances
Too big distance
Formula Student Design and Manufacturing Do and Don’t Decreased compliances with good design
Reduce compliances causes!
Formula Student Design and Manufacturing Do and Don’t Single shear attachment
Big, unnecessary shear forces that will create compliances
Formula Student Design and Manufacturing Do and Don’t Double shear attachment
Better forces distribution Less compliances
Reduce compliances causes!
Formula Student Design and Manufacturing Do and Don’t Rocker attachment not at a chassis node
Formula Student Design and Manufacturing Do and Don’t Damper / Spring unit attachment not at a chassis node
Formula Student Design and Manufacturing Do and Don’t Unnecessary big rocker
Formula Student Design and Manufacturing Do and Don’t Same Rocker Ratio. Lighter
Bigger is not better. Try to make each part light, stiff, simple and cheap to manufacture
Formula Student Design and Manufacturing Do and Don’t Anti Roll Bars are supposed to work in torsion not in bending
Too big distance
Very weak point
Formula Student Design and Manufacturing Do and Don’t Anti Roll Bars are supposed to work in torsion not in bending
Formula Student Design and Manufacturing Do and Don’t Anti Roll Bars compliances ARB bearing cap not at a chassis node
Single shear
Too big Distance
Formula Student Design and Manufacturing Do and Don’t Anti Roll Bars sizes
Formula Student Design and Manufacturing Do and Don’t Anti Roll Bars unnecessary compliances Droop link attachment point in the middle of suspension linkage
Single shear
Formula Student Design and Manufacturing Do and Don’t Anti Roll Bars Design and Installation
Bigger is not better. Do not start manufacturing anything until all drawings
Formula Student Design and Manufacturing Do and Don’t Overcomplicated chassis 6 tubes 2 Nodes ..so close to each other
2 1
A 5
6
3
B 4
Unnecessary complicated
Simple Recipe for good frame design: 1. Triangulation everywhere. 2. Minimum amount of tubes and nodes!
Formula Student Design and Manufacturing Do and Don’t Unnecessary heavy uprights
Heavy
Lighter
Formula Student Design and Manufacturing Do and Don’t Unnecessary long suspension elements The longer each suspension element …. the heavier …. the more flexible
Think - Small - Light - Stiff - Smart packaging
Formula Student Design and Manufacturing Do and Don’t Big, heavy radiator poor efficiency, aerodynamic drag The fan only sucks a small portion of the air going through of the radiator The air will follow the path of a lesser resistance Low cooling efficiency
Does it need to be that big?
Formula Student Design and Manufacturing Do and Don’t A big radiator is needed….
Because low fan use and no side pod ducting
Formula Student Design and Manufacturing Do and Don’t Cooling Efficiency
Light, Efficient, Low Drag!
