Design And Research On Composite Suspension Of FSAE Racing Car

With the rapid development of China’s automobile industry and the improvementof people’s life quality, the purposes of cars are no longer limited to transporting tools,but more about the pursuit of movement, speed and passion given by automobiles. Soall kinds of Motorsport have been produced and racing culture are gradually enteringinto people’s lives. In2010, China held the first formula student racingcompetition(FSAE), and then many universities have started the research,manufacturing and commissioning of FSAE racing cars. In order to promote themushroom growth of FSAE in China, this paper is based on FSAE racing car ofHarbin Institute of technology at Weihai to conduct a study of composite suspensionsystem.According to the racing car’s structure, layout, dimensions, requirements anddesign specifications, this paper determines the type of suspension, alignment andsuspension geometry. Based on all these works, the entire suspension system ispreliminarily designed and a three dimensional model of the suspension system isbuilded.This paper analyses the application of carbon fiber composites in racing car’ssuspension and develops the connection’s scheme between carbon fiber andaluminum alloy connector and finally develops the related test programme. Throughthe design method from orthogonal test, we conduct mechanics experiment of theconnection strength of adhesive, test results is analysed by range analysis, and effectfactors of effect degree order is got on received strength. Carbon fiber tubes’sconnection and the process is studied with metal stamping. The tests for carbon fibercomposites’s using in racing suspension provides strong according on later research.Based on Adams/Car module, FSAE racing car’s front and rear suspensions areestablished, kinematics simulation analysis is carried out. At the same time the wheelalignment parameters and track, roll center height and other important parameters arestudied. Based on Adams/Insight module, wheel alignment parameters, track and rollcenter height are optimized. By selecting the design trial and the target variables,sensitivity level analysis is performed, and optimization results are obtained.Comparing the results before with optimizated results, it proves the necessity ofoptimizing.Based on the whole car’s simulation model, this paper makes Constant RadiusCorner and Fish Hook experimental simulation, through which it verifies theaccuracy of vehicle model and understeer characteristics. According to the simulationresults, analyses offset frequency changes’ impact on whole vechicle’s handling andstability, as well as Fish Hook analysis of different speeds going through the experiment to account for vehicle handling and stability.