2008+Hunan+University+Formula+SAE+West+Design+Report.pdf

HunaUiversityHNURacingFSAEWST58#DESIGNREPOT1208208HunaHunaUiversityUiversityormulaFormulaSSAEW estW WW estDesignDesignReportReport1.1.IntrodctiIntroductinHNURacigTeamisecondyearcompetiorintheFormulaSAEestcompetion.Aftersumingupthexprinofth207ptin,wadsgidelinsofurdig,isuay:liablity:Reliablity:Aterudiscuiofrthe207copetioaftrihin,weadethconlusiontharelilitwasthmotentialdsignmntHNU208.Wntovartisngiredtoltndtbrlibeilcopets.Simplicy:Simplicty:Gthecarunigontiwithailandpractildesignasytomanufctre,orsimplyurhased.Kpitsmplistheky.W W WWigteightRRucioneduction:Carithecarsofthertams,HNU207wastoheavy.Oneoftheostimportanidelisweducingtwigtucpoible.Acrdingtdsig,wlrducweightfHNU208by0k(176lb).EasEaseoofservicngsrvicngadadminteace:minteace:hnsomethingwasrongwithHNU207,ecouldntrepairteilyndquiklysrsultofdsig.WepaidrteiidesigntomakHNU208syfomaitce.Inordetmethserquiremntsadmnufactringdealins,wehavrelidxtensivlyontheusofcputrs.Svraldiftdig,iltio,ptimztio,dmnufctrpackgwrdtenhaeodesignpocesatheablelw.DesignSectionDesignAnalysi/TestingupiadSteringSystemModliiUnigraphics,AutoCD1.micAalysinADMS2.esigndiMtlb3.SiulatoptimzeinLotusSpensioAnalysiIpactenuator 1.imltedinLS-DYNAFrm .UsofPVCoelsfroptization.2.Chaistifncalutin&ptimzationANSY.Powertain 1.Injectorlw-tesdtoetriechrteristc.2.DyamtrapingfECU.3.MtLbeloyedfrivetrainoptimzation.Drivetain 1.ynaicAnalsinADMSAodymics .UseofFluetforteig&optizationErgni 1.CalctdinExcl2.seofPVCmoelsftheframetovalidterivscomfrtandr.HunaUiversityHNURacingFSAEWST58#DESIGNREPOT22.2.DesignDesignReviwReviw2.12.1BrakBrakesSystmSystemThebrakingsyteisgreatimportanforthevicleprfomance.Rliablity,safetyandbrakingpfomcewroufitdsigtsk.Tmaxiztheliblitydsfet,wcosiethelingfats:Indivualhydrauliciruitsforthefrontadtherahveindviualresvoirsfreachiruit.Asaresltwomstelindewmply.Tboftfrotmstcylindi7/10in,dtherboi7/8inch.Tbalcbartnsithefrcwhicaspliedtohepaldistrbutsitotfrntadreasterylindes.Ecrvoiasdiretlyunttmtecylinderaispckgsinglambloateducthepibltofleakgortherdag.Fouriscthesamediio20(8.6in).Frtalirsadulpistnfltinclipwith27m(1.06in)itrpistn,reaclipersasiglepistonfltingcalierwith34m(1.34in)diaetrpisto.Thepedalboxadthbktdeindabritedbystudnts.Tepdalboxiscontuctedfrluminly.Itclevrlyaglsthmstecylinrtogiveitahortverlegth.Witaboveeasr,ourbakstmisbletoakgodpefmanctcktathfrictoneficntrngf0.6t1.,ndthrakdclertincarchto1.6gasximu.2.22.2FrameFrameThecasisbaedonspace-frmeconeptandtheusageof#20(equalsto102-Normalized)tubesnsurnoughtrsitifsdbigriity.Tiwschsnvrthercasitypschamocqecaiduetoitailtyoetainhigefinyitoutdifultdeignaduanuftringpros.Thisyearthmaincosiderationsithedsignoftheframewrthesaftyofthedriv,ergonmics,packgincitervltregt,wictilcsidtsfttemstipotapit.Theetirfaisdignedjustaoundtherive,ginhiorhetrightauntfscendtusducingthelthoftmebrssainofexcswigt.ByusinCAD(Uigraphis)tofithebstomprisebtwndiveCGdcmrtuhasetinpoit,visblity,teringwhelangltc.ThetoalweightofteframewasoptimzedusingtbesoflwerthicknesadODinaresoflwstreicstilmtul.Orglitrcthframigtfom45g(9lb)t32kg(70.5lb),hiavechievd.ThisoalsetbyteoptizedberplacentusiresultofFEAanlysi(ANSY).Analyifthframwasrfforsvlsbyloadingatherntupeionpitswithdmiclods.Thefeasdeignduchtathefrcestdatssiit,engiountsatrivtrinmbliswerfetivlydipatdthrougthetructre,nsurihirldcryingcapity.Thetorintifsothfrmewsefctivlyinasdbytesofcsmebsdfinlfiguf250N/degabtindthrougANSY.TheSpcilfixturwerdigndtoinmizethectowarpofthfreuriteldin.frontimactnatoasiulatediLS-DYNA.ushznemadoalminhoycmbwaspvidesdeigdtbor80joulesfnergy.HunaUiversityHNURacingFSAEWST58#DESIGNREPOT32.32.3BodyBodyThemainistoreducthewightoftebody.Sinceraingotherackinompetionisatreltivlylowspd(60km/hspontavrg),thaodymicsftvhilistiptn.Thebyrasterfoaedtfithefamenswthetyloarcear.Teidaofthebodystlasfohigpdtrbiksanrcigr.Wetdtokthvilstylirntfrmthertem.Athsaetim,ournewvhicleasthenwcharteristcforhigperfomancesfolwing:1.Inordtgtaitoltgi,editoadnitaktihsidthveicl.2.Thewlebodyiseigndacordaerynamicsfrlwersitce.Wmadt1:mlofthebywkfopltioabyCNandmufactredthfinalbodywithfibergls.2.42.4SuspenionSuspenionNatrfqcieswresto2.6Hzand2.8Hzinthefrontadreaspectivly.Higherartewasdetminedorian.Wepsitoerlcetr14mbvgoundithefront,wicthvlu(28)ithe.Theyrtthilwhigtoeducjakinfrce,wiluldevrgoacrsthegroundplandrmainwitnterackinrlvnixtreoditns.Lesonhadlerntfolastyer,adeAnti-RolBarsonHNU208,thusterolgradientwasgretlyimprvt1.02deg/.ThARBswrsigeduchttheycoldbailyjustbyltintoquealenth,rsultinrolateditbutionvaryigfrom40/6t0/4.Suspeniokinematics&dynamicswasimulatednoptizedinADMSandLotusSpensioAalyi.Lgrlik(opreithHNU207)wrselcttomiizeprmetrchag.Frtswingrlenthwaset30.Itasdetrindtokpthefrntwhluightundbrkin.Asareult,cmbrgins.5deg/inbumpa0.79g/diol.TetradofwaslgecatrnglsandiuKPIagl.Wra7degrsofcsteran2ersfKPI.Itforstingarmpckigreason.Adthenlwsthavluthmxiutaicnegativcambe,alwithestrinxiprletoelitltionsrface,wicresltdisymuftr.Whilnthera,tSALwashlvdtabout120m,lightlyrgthanttrackonthesid,becausofcompensatiofteringefctinrl.Besid,uclesbkifoeisgratitr,threslsirtctkpthwelupight.Terltofcamergain1.26deg/inbumpand0.5deg/inol.KS-INDcoil-vershockswermployednfourcners.Oposedpackgewasprefrdforladtransminbalalainizgthetfamtifn.Asforthblcanks,pecilteiowsplcedonthebcusetBiMaconHNU208astoihedvyne.Thredutionfightaaicr.AnalyinANSYprvedthucefligtwigt.KinmaticswasimultednoptimzediDMS,sothemotinatiocangwithnamialfield.Thgoaliurightsignistoreductwigtdkeptheoustregth.TrontareuprightwsdebyaliuawvrysiplesinforasytprcbyCNachig.RitaigntoTshpeforteaon.Oatelgetoasewelslimntibumpster.Theotrwastincrauightsifsbysplitnguprldti-rodanuprA-ars.HunaUiversityHNURacingFSAEWST58#DESIGNREPOT42.52.5SteringSteringSystemSystemAcorditohtaslttyredatndcalutions,wechosetuseprster.Byusingthepositvekeman,teHNU208habhieviglrtringamthanteHNU207.ThHNU208usdthrackousingstHNU207hicadbeodifetoreducitswightobviuslybyusingalinmtethplaceofstel.Bygivnfilstringratibt4:1,andkepingthemisterigdiatrobut7m,waiedatigthedivsteingithpromtrsowithoutbintoifcultster.?WeusdADMSforsimulationdoptimzationtgethacurtedatndmialchngeofteangldringwhelbup.OtiztiiMtlbsurromtylost10%Akerwichprvidsoadlingadtheabiltyforsharpcorne.2.62.6PowertaiPowertainTheHNUispowerdbyaJilngJH60F2engi,anupgradefromtheonistaledin207.ThengiaignficatimprovetsuchastcylidrECU.Theintakemnifoldhasbenspecialydesigndtoreucloseandmxizethvolumeflowrateintotgi.Aaircrwadigntomakitaprrtble,iordtrdcthinlucfpresurwvestohesnosreucthenisofthexaustyt.Theantoy20airtketicoprFSErulatignod.Wit20mrticontirtkebtwenthotlandthengie,thpowetpuisevrlyited.Inodetireasthepowutpilstrticed,trsticorasgivnastrmlindfotaclrathratoftfl.Thefulsytemhasbeniplentdasneficnt,loweight,lowcstandperfomanceorinteddsign.hfultkwdsigtopthbodyafrmftraigrstlwsltasthepriayterialofitbthuetisueristrength,stableonhtindloerpice.Italoeytomnufctfcmplexsaping1.5mtlt.Thecolingsyteiscopsedofarditorwithafnmoutedontheback,noverflwbotleandlatlie.Thraditrinthetcmentsotegi.Aslargoetiaisnforhigficny,teitowasloctdinthidfthbody,whicibtrfthegicmpaedwitpreviousarscr.WearusingamodifestockmuflertoprvideagodpackginfortherpatsuchasteA-arms,CVndhlfft.Oripr