Catia design for the front upright for an electric powered lightweight single seater race car.

This is an individual assignment whereby you have been tasked by the Racing team to design the front upright for an electric powered lightweight single seater race car. The race car features all-wheel drive and each wheel assembly has its own outboard mounted electric motor and epicyclic gearbox. The team are downsizing their wheels from 13” diameter to 10” diameter wheels and have chosen to use a commercially available 10” magnesium wheel to fit a Hoosier 18.0 X 7.5 -10 slick racing For the purposes of the assignment, CAD and a technical drawing of the OZ 10” Magnesium wheel is provided, the latter can be viewed online here. This will allow the accurate representation of the inside of the wheel and gives sufficient detail for the mounting face of the wheel hub. The design of the existing brake disc and spider to fit the 13” wheel is also provided for reference. You are provided with load case details in table 1 for the four contact patches of the car. Using this you must carry our stress analysis on your design to help improve the stiffness to weight ratio of your final design. Corner Normal Load (N) Lateral Force (N) Longitudinal Force (N) FL 4200 +/-1400 +1500 FR 4200 +/-1400 +1500 RL 4600 +/-1550 -1000 RR 4600 +/-1550 -1000 The manufacturing constraints limit the range of material for the upright to steel or aluminium. The following materials are available; Aluminium billet: 2014 T6, 6061 T6, 7075 T6 Steel bar: EN3b, EN8, EN16, EN24T Steel plate: mild steel (S275) & T45. Furthermore, the manufacturing techniques must be readily available in the UK. Your design must incorporate a commercially available brake caliper, the team have selected the AP Racing 4 piston CP4227-2SO at the front and the AP Racing 2 piston CP4226-2S0 at the rear. The engineering drawings of the caliper can be viewed here. The CAD part file is also included in the resources provided. The design of the epicyclic gearbox is an integral part of the upright and the CAD for this is provided along with a bearing housing profile that must be retained. You are not required to specify the wheel bearings that will be used as these are accounted for in the bearing housing profile provided. You are responsible for the design of the upright which can include a clevis if using a multiple piece upright. The design must integrate a floating disc brake that can mount to the existing hub. Comment on how the hub design would need to be modified to secure the proposed wheel design. You must include all fasteners required. The Product Design Specification for the new wheel assembly is as follows: Performance: The product must withstand forces associated with a racecar with total mass of 300kg, a 48:52 front to rear weight bias achieving 2.0g lateral acceleration, 1.5g longitudinal acceleration and 3g bump. The product must allow OZ 10” FS wheels to be used The product must allow for outboard brakes to be fitted. The brakes must allow the driver to be able to lock the wheels. The product must facilitate a floating disc brake with minimum OD of 190mm. The product must accommodate brake torque up to 500Nm The products must allow camber settings between 0 to -4 degrees. The product must have between 6-8 degrees of caster angle. The product must have no more than 3 degrees of kingpin inclination angle. The product should have a scrub radius no more than +60mm Environment The car will mainly be used in UK weather conditions. Temperature ranges: 0 degrees C – 40 degrees C The product may be used in humid conditions The product may be exposed to dust and dirt. Corrosion resistance must be included. The product will be exposed to vibration from the powertrain as well as vibration from the road input. Life in Service The product is expected to cover 2000km in service. Customers The product needs to be reliable and easy to maintain