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Presented By: Neil Barnes Nick Hatcher Kevin Feeley Andrew Taylor

ME 450: Analysis of Suspension Rocker and Redesign. Presented By: Neil Barnes Nick Hatcher Kevin Feeley Andrew Taylor. 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.

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Presented By: Neil Barnes Nick Hatcher Kevin Feeley Andrew Taylor

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  1. ME 450: Analysis of Suspension Rocker and Redesign 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 Area of Interest

  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 4.521+3.099 mm R5.000+1.350 mm R5.000+2.000 mm

  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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