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Validation of Key Parameters Between Real and Computer Model of Suspension System Used in FSAE Vehicle

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Ziemba K. , Tracz J. , Rządkowski W. , Kowalik M.

Advances in Science and Technology. Research Journal

2020

tom Vol. 14, no 3

65--74

The aim of this paper was to determine the differences in the designed and manufactured model of a suspension. A set of key parameters was compared, including camber and toe in angles and their change w.r.t wheel travel, as well as the motion ratio. It also focused on the possibility of accurately determining the suspension system kinematics using affordable measuring devices available on the market. First, the design process, main goals and project assumptions were briefly described. Next, the CAD model and manufacturing process was presented. Finally, the measurements of both computer and real model were performed. The obtained results were compared and a significant difference between models was observed. The reason of such variation could not be determined unambiguously, as there were numerous factors that could potentially influence the results. Moreover, it was proven that accurate determination of kinematics is impossible using the given set of measuring devices.

Case Study of Composite Chassis Manufacturing Process Using Low Temperature Molds Tempered with Gradual Heat Annealing Process

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Rządkowski W. , Klik P. , Tracz J. , Kowalik M.

Advances in Science and Technology. Research Journal

2022

tom Vol. 16, no 3

12--21

This case study describes a manufacturing process of composite chassis also known as monocoque. The structure is made using carbon fibre reinforced polymers (CFRP) which are manufactured in out-of-autoclave (OOA) process from pre-impregnated carbon fabrics and aluminium alloy honeycomb core. Since the material cost is high the aim of the project was to reduce the cost of manufacturing process i.e. cost of models and moulds. Therefore, instead of high-temp models and moulds a cheaper alternative was used. It consisted of Styrofoam models made using polyurethane (PU) paste and moulds made from CFRP using wet layup process which were cured at room temperature. Such moulds had to be adapted to withstand high temperatures during pre-preg cure. This was done with gradual heat annealing process which increased the maximum service temperature from 45C to 90C. This was enough for the low-temp cure of pre-preg material, but it might be possible to increase the temperature even further. As a result, the cost of manufacturing process had been reduced by 50%.