Formula SAE Interchangeable Independent Rear Suspension Design

........................................................................................................................................................ 6 Chapter 1: Introduction ............................................................................................................................... 7 FSAE Team History and Opportunity ......................................................................................................... 8 Formal Problem Definition ...................................................................................................................... 10 Objectives/Specification Development ................................................................................................... 11 Chapter 2: Background ............................................................................................................................... 13 Solid Rear Axle Design ............................................................................................................................. 14 Tire Research ........................................................................................................................................... 15 Steady State Cornering Model ................................................................................................................ 16 Chapter 3: Design Development ................................................................................................................ 19 Suspension Geometry .............................................................................................................................. 20 Loading Conditions and Forces ............................................................................................................... 22 Space Frame Adaption ............................................................................................................................ 23 Differential .............................................................................................................................................. 27 CV Joints and Half Shafts......................................................................................................................... 28 Uprights ................................................................................................................................................... 30 Chapter 4: Final Design ............................................................................................................................... 33 Summary and model ............................................................................................................................... 34 Detailed Design Description and Analysis ............................................................................................... 36 Rear A-Arms ........................................................................................................................................ 36 Rear Rockers ....................................................................................................................................... 39 Shocks and the Anti-Roll Bar (ARB) ..................................................................................................... 40 Front Suspension Analysis and Redesign ............................................................................................ 41 Rear Frame Adaptation ....................................................................................................................... 43