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Redesign of Lotus Europa Front Suspension

Redesign of Lotus Europa Front Suspension ME 450: Finite Element Analysis Spring 2007 Presented by: Bart Sudhoff, Zachary Lightner, Jim Milligan, Brian Schludecker, David Giles Dr. Nema 4/30/2007 Summary & Introduction Redesign Front Suspension Upper Control Arm

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Redesign of Lotus Europa Front Suspension

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  1. Redesign of Lotus Europa Front Suspension ME 450: Finite Element Analysis Spring 2007 Presented by: Bart Sudhoff, Zachary Lightner, Jim Milligan, Brian Schludecker, David Giles Dr. Nema 4/30/2007

  2. Summary & Introduction Redesign Front Suspension Upper Control Arm Top Speed Increase: 120 to 200 MPH Design Issues: New weight of car due to increased engine size New handling characteristics

  3. Original Design • Built in 1970 • 1470cc OHV 4 Cylinder Engine – 78HP • Front Wheel Drive • 4-Speed Transmission • Curb Weight: 1320-1570lbs • Top Speed 120 MPH

  4. New Design • Engine: Lexus V8 4.0L Quad Cam • Transmission: Porsche 5-Speed • Suspension: New Design of Lower/Upper Control Arms, Springs, Shocks • Factor of Safety of 5 • Light Weight • Minimal Deformation

  5. Theoretical Background • Decomposition of model into stiffness, force matrices • Solution in form of nodal displacement matrix • 4-node tetrahedral element displacement solution

  6. Model Details • Upper and Lower Control arms modeled using Pro/E • Constraints • Fix – about the mounting holes • Forces applied at ball joint

  7. Model Details

  8. Model Details

  9. Model Details

  10. Results • 2” thick arm • Stress - 20.06 MPa • Deformation - .102 mm • Safety Factor – Greater than 10

  11. Results • 1.75” thick arm • Stress - 25.1 MPa • Deformation - .128 mm • Safety Factor – Greater than 5

  12. Results • 1.75” thick arm with relief • Stress - 18.9 MPa. • Deformation - .131 mm • Safety Factor – Greater than 5

  13. Results • 1.5” thick arm with relief • Stress - 24.4 MPa • Deformation - .184 mm • Safety Factor – Greater than 5

  14. Results • 1.5” thick arm with relief • Vertical Bump • Stress - 3.82 MPa • Deformation - .0229mm • Safety Factor – Greater than 10 • Rebound • Stress - 14 MPa • Deformation - .106mm. • Safety Factor – Greater than 10

  15. Conclusion • Chose 1 ½” control arm with relief cuts • Passed factor of safety tests • has allowable deformation • Will allow car to go 200 mph

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