Formula SAE Rear Suspension Design

Introduction

• Presenter: Fred Drasa
  • Senior, President and Chief Engineer of Chipa Racing Formula SAE Team
  • Senior design project focuses on rear suspension of a Formula SAE car
• Interest: Kinematics in suspension systems

Rear Suspension Design

• Core Concept: Multiple kinematic relationships within one suspension system
  • Includes motion of push rods, can levers, and sway bar

Key Components and Changes

• Existing Components:
  • Push rod, can lever, and shock will remain the same as last year.
• New Additions:
  • Sway bar and sway bar link
  • Sway bar connects to the back and to the can lever
• Modifications:
  • Toe adjuster relocated from bottom to top for easier access
  • Can lever mounted on an oblique plane, not parallel
  • New design will compress the shock by pushing it backward

Sway Bar System

• Purpose: To prevent car rolling
• New Feature: Sway bar will:
  • Attach at two points in the back and run the length of the car
  • Connect to the can lever, which has a fourth point
  • Distribute weight evenly across tires when rolling occurs

Testing and Simulation

• Design Evaluation: FEA (Finite Element Analysis) is conducted on CAD parts
  • Ensures no excessive deflection or yielding
• Manufacturing:
  • Components are easy to remake if needed
• Testing Timeline:
  • Two-week testing phase before racing

Project Timeline

• Design Phase: Started at the beginning of the year
  • Two-semester senior design project
  • First semester: Design
  • Second semester: Manufacturing
• Manufacturing Schedule: Begins within first month of returning to school

Summary

• Design portion is complete, focusing on manufacturing for the next semester
• Aim to enhance vehicle stability and performance with new suspension system

This project highlights the complex kinematic relationships in suspension design and the iterative process involving design, simulation, and testing.