Lightweight Design for a FSC Car Based on Modal and Stiffness Analysis
Based on the stiffness and vibration modal analysis for a FSC racing car frame with the FEA method and testing evaluation, the design parameters of optimal tubular space frame were determined through the sensitivity analysis. Oriented the minimizing the f
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Abstract Based on the stiffness and vibration modal analysis for a FSC racing car frame with the FEA method and testing evaluation, the design parameters of optimal tubular space frame were determined through the sensitivity analysis. Oriented the minimizing the frame weight, the thickness of tubes was conducted under meet the requirements of stiffness and vibration modal. As a result, the frame weight was deceased by 7.18 %. Keywords FSC racing car frame Sensitivity analysis Lightweight
Modal analysis
Stiffness calculation
1 Introduction The FSC racing car frame is the installation base of the overall car assembly, which bears the gravity of all kind assembly such as engine, care body, wheel and tire, suspension and driver. Moreover, it bears the complex loads between the road surface and tire. The frame structural strength and dynamic characteristics have a great influence on the driver safety, power performance, handling and stability, ride comfort as well as other aspects of the car. It is necessary that frame structure possess sufficient stiffness to ensure the assembly accuracy of the motion system
F2012-E09-012 L. Jiang (&) G. Wang G. Gong R. Zhang Beijing Information Science and Technology University, Beijing, China
SAE-China and FISITA (eds.), Proceedings of the FISITA 2012 World Automotive Congress, Lecture Notes in Electrical Engineering 196, DOI: 10.1007/978-3-642-33738-3_6, Ó Springer-Verlag Berlin Heidelberg 2013
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and operating requirements. At the same time, the frame must have excellent dynamic characteristics to suppress vibration shock and reduce the noise [1]. Due to the power limitation, the frame should be lightweight as much as possible in order to increase the acceleration capability and better fuel efficiency.
2 Establishment of the Finite Element Model of the FSC Car Frame In this chapter, the geometric model of the car frame was established by CATIA software, as shown in Fig. 1, it was a tubular space frame which designed according to the Rules of the Formula Student of China [2]. Then the model was imported into HyperMesh software to establish the corresponding finite element model. To reduce the calculation scale, the fuel tank, engine radiator and some smaller parts were left out on the premise as the small influence on the main mechanical properties of the frame. The finite element model was shown in Fig. 2. The tubular space frame was welded steel tube. Since the tube wall is thinner, the methods of extraction the middle surface was used while meshing the element grid and the shell element was an average element size of 5 mm. Welding among circular tubes was simulated by shared nodes, while other soldered dots replaced by Spot-weld (1D element). Engine, differential gear, wheels, steering wheel and the driver were replaced with the lumped mass CONM2, which acted on corresponding nodes through the RBE3 element. The frame material is 30 CrMo, and the modulus of elasticity, the density, and the Poisson’s ratio are 2.11 9 105 MPa, 7.9
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