Catia design for the front upright for an electric powered lightweight single seater race car.
£20-250 GBP
Paid on delivery
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
Project ID: #33582386
About the project
11 freelancers are bidding on average £230 for this job
Hi there,I'm biddin on your project "Catia design for the front upright for an electric powered lightweight single seater race car." I have read your project description and i'm an expert in Mechanical Engineering doma More
Hi, I hope you are doing fine. I have PhD in mechanical engineering from Tohoku University of Japan. I have published 20 Journal papers and 16 international conference papers. I have a lot of experience in automotive, More
Hi there, I am a mechanical engineer with expertise in Design, CFD and FEA. I have done similar kind of design and analysis. I can do this task perfectly. Please open the chatbox to have detailed discussion. Thanks, More
I am a mechanical engineer. I enjoy designing and this is one of my dream since elementary days and also i would like to push my skills and talent beyond the limit.
Hello I’m Navid from Sweden. I have a good knowledge in automotive industries. I have designed many parts, some of which includes basic requirement ( Start BD , PD , DFA , DFM , QFD , DFMEA according to IATF 16949 : ch More