Search Results

High performance vehicles are subjected to a high level of loads during short time intervals. Due this situation, manufacturing procedures that conventionally are used in the automotive industry commonly do not achieve the design specifications defined to maximize the overall performance of the vehicle. This situation is highlighted when the overall performance of the system depends on a compromise between variables. The research developed by a German motorsport team aimed to fix the overheating problem found on the front brake system of a Formula SAE prototype using topology optimization combined with the manufacturing processes called Direct Metal Laser Sintering (DMLS) to develop and fabricate a new 4 piston monoblock brake caliper. The DMLS process is based on powder metallurgy, using an Yb-fibre laser to melt a powder material and generate the product by a progressive deposition of layers.

In the present paper, a typical Formula SAE double-wishbone suspension is discussed. This study aims to point out a preliminary chassis setup to reduce testing time on track and improve the overall performance of a prototype in a Formula SAE Skid Pad event. The influence of kinematic parameters of the suspension are analyzed to quantify how they change the capability of the tire to generate lateral force due to camber effects. To enhance results, special attention is given to a Magic Formula tire model based on a constrained forces and moments tire test data. Camber and Ackermann steering geometry showed up as major tuning tools to attempt during test period.