International Research Journal of Engineering and Technology (IRJET)
Volume: 08 Issue: 08 | Aug 2021
www.irjet.net
e-ISSN: 2395-0056 p-ISSN: 2395-0072
Design and Fatigue Analysis of Upright on FSAE Vehicle Priyank Kothari1, Elton Dias2, Soumya Chaphale3 1-3Dept.
of Mechanical Engineering, Vishwakarma Institute of Information Technology, Pune, India ----------------------------------------------------------------------------***-----------------------------------------------------------------------Abstract: Formula cars have to go through lot of mechanical stress for which components of the system needs to designed and optimized properly. Suspension in a car plays a important role to maintain car stability at higher speeds and even during cornering. which are all assembled to form a functional system. Design of knuckle was done in SolidWorks and analysis was done in Ansys. Weight reduction on part is significant as to increase vehicles performance, increase fuel efficiency which is done through many topological improvements. KEYWORDS: FSAE, upright, suspension, Hexa core mesh, ANSYS, SOLIDWORKS, Total deformation, Equivalent Stress. 1. Model: The Rear knuckle is modelled using SolidWorks. Taking reference of the team’s older designs, a newer design was needed which had to not only be structurally strong but also lightweight. Using good engineering techniques, we created the knuckle suitable for the car’s suspension geometry and the parts used in wheel assembly. Figure 3- Assembly in SolidWorks 2. Material: Before taking the parts through the initial stress and deflection calculations, the material needed to be considered. Only aluminium alloys were considered due to the low weight, ease of manufacturability, and low cost. Through research, 7075-T6 aluminium, a strong aircraft grade aluminium was preferred, although the material needed for the knuckle would be greatly out of the project budget. Other alloys were researched, and 6061-T6 proved to be just as light, while retaining an acceptable strength, with a significantly lower cost. Therefore aluminium 6061-T6 was selected for manufacturing the knuckle. Density Tensile ultimate Figure 1- Front upright
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Figure 2- Rear Upright
Impact Factor value: 7.529
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2700 kg/m3 strength
310 MPa
Tensile strength yield
275 MPa
Modulus of Elasticity
70 GPa
Poisson Ratio
0.33
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