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Redesign of Lotus Europa Front Suspension

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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

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

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

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

    18. 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

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

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