Design and Analysis of Suspension System for a Formula SAE Race Car

The objective of this project is to further optimize the suspension system of a Formula
SAE race car with steering system included. The suspension system is designed based
on unequal length double wishbone suspension system. Several changes had beenmade
for the new car with the usage of hybrid composite-spaced frame chassis and single
cylinder engine. Thus, new design concepts has been introduced to suit the changes
made for the vehicle which include the changes in mounting points, weight distribution,
suspension kinematics plane,and steering geometry.
The scope of study consists of modeling the suspension and steering components by
using computeraided softwaresuch as CATIA. In addition, the Finite ElementAnalysis
(FEA) is performed by using CATIA which could give instantaneous yet accurate
results. Dynamics analysis will compromise the usage ofADAMSCAR software which
can simulate the whole suspension and steering system behavior according to the track
layout which will make better understanding regarding the study. Although the
fabrications of the actual product will not being carried out, the fabrication method will
be inserted together in this study as reference for future planning.
Based on the designing and analysis performed, the calculated roll center height and
static camber angle ofthe vehicle at the static position is -68mm from the ground and -
0.5 degree respectively. In addition, the maximum lateral load transfer being transferred
during cornering with radius of7.5 meters is 91.82 N. The dynamics analysis performed
in ADAMSCARS shows remarkable results in open loop step steer simulation. These
results provide better understanding of the vehicle performance during the autocross
events.