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Redesign of Lotus Europa Front Suspension PowerPoint PPT Presentation

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 l.jpg

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


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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


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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


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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


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Theoretical Background

  • Decomposition of model into stiffness, force matrices

  • Solution in form of nodal displacement matrix

  • 4-node tetrahedral element displacement solution


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Model Details

  • Upper and Lower Control arms modeled using Pro/E

  • Constraints

    • Fix – about the mounting holes

    • Forces applied at ball joint


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Model Details


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Model Details


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Model Details


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Results

  • 2” thick arm

    • Stress - 20.06 MPa

    • Deformation - .102 mm

    • Safety Factor – Greater than 10


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Results

  • 1.75” thick arm

    • Stress - 25.1 MPa

    • Deformation - .128 mm

    • Safety Factor – Greater than 5


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Results

  • 1.75” thick arm with relief

    • Stress - 18.9 MPa.

    • Deformation - .131 mm

    • Safety Factor – Greater than 5


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Results

  • 1.5” thick arm with relief

    • Stress - 24.4 MPa

    • Deformation - .184 mm

    • Safety Factor – Greater than 5


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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


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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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