Graduate Thesis Or Dissertation
 

Race Car Monocoque Design? A Loaded Question Suspension Kinematics, Loads & Sandwich Panel Optimization Methodologies

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https://ir.library.oregonstate.edu/concern/graduate_thesis_or_dissertations/jh3441213

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  • As designers continue to develop the ability to improve a component or system design relative to any number of metrics, priorities and objectives, the need for advanced methodologies which focus efforts and steer design decisions to best meet the needs of the organization becomes increasingly important. This work develops such a methodology, focusing on the weight reduction of a composite monocoque for a Formula SAE (FSAE) / Formula Student car, considering stiffness performance targets, strength and rules-mandated safety requirements, and impact on team resources. Suspension load calculations techniques necessary for global and local chassis design as well as related vehicle components are developed, common race car suspension types are considered, and tools created to aid in suspension link load analysis using vehicle parameters, dynamic maneuvers, and accelerations. Loads calculated at static ride height are compared to identical load cases while accounting for suspension kinematics to inform the designer of the risk of static ride height assumptions. Spreadsheets, Computer Aided Design (CAD) and Finite Element Analysis (FEA) softwares are used for calculations, and procedures are included to aid in replication. Finally, a method is proposed for the mass optimization of a Formula SAE chassis, combining a bespoke composite sandwich panel design and selection process with FEA and a team-developed objective function.
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  • Intellectual Property (patent, etc.)
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  • 2021-07-03 to 2023-08-03

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