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Presented By: Neil Barnes Nick Hatcher Kevin Feeley Andrew Taylor

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Presented By: Neil Barnes Nick Hatcher Kevin Feeley Andrew Taylor

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    1. Presented By: Neil Barnes Nick Hatcher Kevin Feeley Andrew Taylor

    2. Objectives To redesign the front suspension rocker for the #4 Delphi Panther Racing Indycar. To reduce weight of front rockers by ½ a pound each. Constructed using Aluminum rather than Steel.

    3. Introduction Rocker used in front suspension for Indy Racing League Maximum Load = 7000 lbs Verified by DAG team at Panther Racing Constructed rocker in Pro-engineer Analyzed in ANSYS Workbench Analyzed stresses on steel rocker Resigned rocker in order to minimize stresses Constructed rocker from Aluminum

    4. Front Suspension Rocker

    5. Theoretical Background Centrifugal Force

    6. Theoretical Background Solid 92 (Tetrahedral Solid) 10 Nodes, 3-D Space DOF: UX, UY, UZ WORKBENCH default element

    7. Theoretical Background Local equation of Force: {f} = [K]{u} Local equation (expanded 2D) Transformation Matrix

    8. Theoretical Background Finding Global Stiffness Matrix (Moaveni) Global Equation (expanded 2D) Stress-Displacement Relationship

    9. Theoretical Background Stress-Strain Relationship

    10. Model Details Pro-Engineer Solid Models Converted to SAT format for ANSYS Workbench

    11. Model Details Fine Mesh 47,039 Nodes 24,657 Elements

    12. Boundary Conditions Fixed Support Zero Displacement Rotational Motion Only Force of 7000 lb Directed Outward

    13. Results and Discussion Original Rocker Steel Maximum Stress 88.4 ksi Both sides of hoop

    14. Results and Discussion Modified Rocker Aluminum Increased Radius of hole by 1.35 mm Increased Outside Radius by 2 mm Reduced Stress 79.28 ksi

    15. Results and Discussion Further Modified Rocker Aluminum Increased Thickness by 3.099 mm Reduced Stress 65.05 ksi

    16. Impact Statement Redesigning the front suspension rocker has given Panther Racing an edge on the competition by reducing the weight of the car while keeping the driver safe. Even though it is a very small amount of weight that is being lost, anything that can be lost from the car in terms of weight can give that extra thousandth of a second that is needed in order to beat the competition.

    17. Conclusions Modifications of Original Steel Rocker reduced stresses by approx. 30% 7000 Series Aluminum could successfully be used! Maximum Stress = 65 ksi Increasing Diameters, Radius, and Thickness Reduce Stress Around Hole

    18. References Incropera, Frank, David Dewitt, and Theodore Bergman. Fundamentals of Heat and Mass Transfer. 6th. Hoboken NJ: Wilet & Sons, 2007. Nematollahi, Khosrow. "Oncourse, ME 450." Scheduled Reading and Assignments. IUPUI. 23 Nov 2007 <https://oncourse.iu.edu/access/content/user/knematol/Filemanager_Public_Files/ME450LectureNotesCh13r>.

    19. Questions?

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