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ABSTRACT
The goal of the present work was to develop a dynamic model to provide the engineer with the possibility to incorporate
the elastic deformation of some suspension components into vehicle simulations. This work will focus on a particular
type of vehicle: a Formula Student prototype.
An introduction to the Formula Student competition and the team from Instituto Superior Técnico was the first focus of
this work. An evaluation of the current state of simulations including the effect of compliance in the dynamics of the
vehicle was done next. The model that allows the engineer to evaluate the vehicle’s performance was developed next.
This model uses the different subsystems of the vehicle to return the main performance variables like the accelerations,
velocitys, trajectory angles and the vehicle’s trajectory. The driver inputs (steering wheel and pedals) are also the main
inputs of the model. Next, a decision was taken in regard to the approach to include compliant components along with
the parameters that would be affected. The compliant components were chosen and presented along with a revision of
their design to obtain the deformations.
Finally these compliant parts were incorporated in the model and simulations were run to verify the influence of
compliant components.
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instead of the perfectly kinematic relationships The other slip quantity is not an angle and is a
obtained from kinematic multibody simulation. percentage of the slip of the wheel in the xtzt plane.
Kinematics and Compliance testing is an expensive The tire longitudinal slip ratio, SL, is defined as a
effort for a Formula Student team, and there is no percentage by dividing the tire longitudinal slip
capable machine in Portugal to perform said tests. velocity by the reference wheel-spin velocity:
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The steering axis is defined by the pickup points at the K S kS MR2 (3)
wheel of the upper and lower wishbone for a double-
wishbone suspension. The two important angles are the The same methodology can be assumed for the
kingpin inclination angle, KPI, and the caster angle, ν. effective damper mounted between the wheel center
These angles contribute to the change of camber angle and the tire, CS.
when steering the wheel.
Regarding roll behavior, usually some race cars are
equipped with anti-roll bars (ARB), which is the case
of the FST 05e. To calculate the equivalent spring
between the wheel center and the tire that represents
the ARB one needs to first traduce the equivalent
torsional stiffness of the bar to a linear stiffness, kARB,
and then apply the motion ratio of the wheel/ARB
Figure 4 - KPI and Caster angles couple to get the equivalent stiffness, KARB.
A relevant point in the design process and simulation is In (4), KϕARB represents the torsional stiffness of a bar
the instantaneous center of rotation of the suspension in as in (Beer, Jr. et al. 2011).
2D. This point is defined for each wheel. The angles
defined below are used to compute jacking forces that 4 MODEL DEVELOPMENT –
contribute to anti-roll, anti-dive and anti-squat and anti- WITHOUT COMPLIANCE
lift behavior.
4.1 DRIVER INPUTS
Since the FST 05e is a fully-electric powered vehicle
and the gearbox has a single gear ratio the only inputs
considered from the driver will be the pedals (% of
pedal defelction for throttle pedal and kg of force for
brake pedal) and the steering wheel (input degrees).
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transfer, include migrating instant centers and better
represent the anti-features.
4.3 AERODYNAMICS
To treat the aerodynamic forces, the approach taken in
this work requires the knowledge of the drag and lift
coefficients, the area of the wings and also the position
of the aerodynamic devices with respect to the center
of gravity. In order to translate the aerodynamic forces Figure 9 - Vehicle vibrational model
to the wheels the approach taken in this work is to
define an aerodynamic reference point to which all the Drawing a free-body diagram of each mass system, one
aerodynamic forces are translated. This results in a can compute the above presented matrices and
point that has all the drag and lift forces and no organize the generalized forces vector. The generalized
moment: forces vector is computed with knowledge of the
aerodynamic load distribution and the accelerating
conditions of the vehicle to compute the consequent
weight transfer. The weight transfer is separated in
several effects for easier computation. This is shown
below:
With this reference point defined one can add the mUS .a y .hCGUS
acceleration caused by the drag force to the Fz (11)
acceleration caused by the tire forces and distribute the t
lift force between the four wheels according to the xRP
position. This defines the lift distribution for use in the Fz Fy tan Right Side (12)
vibrational model:
Fz Fy tan Left Side (13)
xRP
LD WD (8)
l
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mS .ax .hCGS The brake system is modeled to receive the input force
Fz (14) of the driver’s foot and translate it to torque applied to
l
the wheel through use of the several parameters that
Fz Fx tan Braking Front axle
define the components of the brake system. This
(15)
braking torque is then reacted at the contact patch by
the tire longitudinal force which generates a
Fz Fx tan Braking Rear axle (16) deceleration in order to slow the vehicle’s speed.
Fz Fx tan Driving Rear axle (17) To calculate the longitudinal force at the contact patch
one needs to calculate the longitudinal slip ratio. This
is done by analyzing the rotational dynamics of the
For the aerodynamic lift:
wheel:
Fz L. LD Front Axle (18) Twheel Fx Rwheel
wheel (23)
I wheel
Fz L. 1 LD Rear Axle (19)
By calculating the angular acceleration of the wheel
4.5 DYNAMICS OF A PARTICLE IN NON- when subjected to the moments described above, one
UNIFORM CIRCULAR MOTION can once again use the Simulink environment
advantages of looped systems, differentiation and
A vehicle moving around a track can be described as
integration. By differentiating the angular acceleration
an object with a certain linear velocity of its center of
one obtains the wheel angular velocity, which serves as
gravity and also an angular velocity around this same
an input to the longitudinal slip ratio calculation as
point. As described in (Beer, Johnston et al. 2006) one
described in chapter 2.
can define an instantaneous center of curvature for this
vehicle in the following way:
4.7 VEHICLE L ATERAL DYNAMICS
The steering wheel input of the driver is translated to
steering rack displacement using the c-factor explained
earlier:
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IA IA 4.8 VEHICLE A CCELERATIONS
IAFR IAstatic , FR z ( zwheel , FR zstatic )
FR
wheel The tire horizontal forces must be transformed from the
IA IA wheel coordinate system to the vehicle coordinate
IAFR IAstatic , FL ( zwheel , FL zstatic )
zwheel FL system:
(27)
IA
IARR IAstatic , RR ( zwheel , RR zstatic ) FYi Fy cos i Fx sin i
zwheel (31)
FXi Fy sin i Fx cos i
IA
IARL IAstatic , RL ( zwheel , RL zstatic )
zwheel To calculate the accelerations of the vehicle the
following calculation loop is used:
The inclination angle variation with the vertical wheel
movement is obtained using the 3-point method along a
normalized wheel travel distance.
Looking at the figure above, the goal of this method is Figure 15 - Calculation loop schematic
to calculate points 1 and 2 knowing points 4, 5, 6, 7
m vx vy
and 3 and also their distance to the unknown points.
This is done solving the equations below. F X (32)
d132 x1 x3 2 y1 y3 2 z1 z3 2 F Y m v y vx (33)
L1 4 2 x1 x4 y1 y4 z1 z4
2 2 2
2 M I zz (34)
L15 x1 x5 y1 y5 z1 z5
2 2 2 Z
d 2 3 x2 x3 y2 y3 z2 z3
2 2 2
2
(28) To obtain the vehicle velocity, the magnitude variation
of the velocity vector is integrated. The longitudinal,
L2 6 x2 x6 y2 y6 z2 z6
2 2 2 2
lateral and angular velocities can then be used in the
L 2 x x 2 y y 2 z z 2
27 2 7 2 7 2 7 calculation of the longitudinal slip ratio and slip angle
as explained earlier.
S .t. x1 x2 y1 y2 z1 z2 d1 2
2 2 2
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Longitudinal slip ratio. will only withstand axial loads – compression or
tension. These loads are calculated as described in 5.2.
Changes in these parameters result in a difference in
tire horizontal forces and tire moments. Thus this work In the case of steel or aluminum wishbones one can
attempts to quantify deformations in suspension simply use Hooke’s Law to compute the extension and
components that can influence these parameters and consequent elongation of the links:
have an effect on tire forces and moments.
F
The slip angle is a parameter directly influenced by the
E A (37)
steering system. The deformations in the steering l l0
system from the steering wheel to the tie-rod influence
the slip angle compliance.
In the case of CFRP suspension links like the ones
By modeling the wishbones as deformable present in the FST 05e, one needs to obtain a way to
components, one can calculate new KPI angle gains compute this elongation. The CFRP link is composed
that directly influence the inclination angle. by aluminum inserts (containing the spherical bearings)
bonded to the carbon fiber tube.
5.2 LOAD CASES CALCULATION
The loads on the suspension components arise from
direct reactions to what happens at the contact patches
of the tires. To calculate the loads on wishbones and
tie-rods a Simulink model of the suspension is built. By
introducing the contact patch forces and moments the
model is equipped with joint sensors that calculate the
load in each link of the suspension. The tie-rod links
forces are used to calculate the force in the steering Figure 17 - Suspension link cut-view
rack and then the torque presented in the steering
pinion is computed: To calculate the deformation of the adhesive one needs
to compute the stresses in the adhesive, which are not
c factor constant along the length of the adhesive joint as in
Tsteering Frack (35) (Adams, Comyn et al. 1996). This behavior was first
2 approached by Volkersen in 1938 and consists on one
of the oldest theories to analyze single-lap joints taking
5.3 DEFORMATION A NALYSIS into account the stiffness of the adherends. Due to its
The steering shaft is designed as a constant section simplicity, vast literature sources and the available
component in the FST 05e. adhesive properties it was the technique used by the
team to design the bonded joints.
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To use this theory for the design of the suspension The following tables show the results obtained
links the approach taken was to use the cylindrical compared to the theoretical approach explained earlier.
shape of the bonding area and treat it as a single-lap
joint with the following characteristics: Table 1 - Results comparison
Tube ID = 18 mm
TD h
w 2 i adhesive (39) Load (kN) Strain Exp Δl (mm) The Δl (mm) Rel. Error
2 2 1 0,000245 0,017125382 0,00594
3 0,000734 0,051376147 0,01783 65%
5 0,001223 0,085626911 0,02971
TDi ID
t2 hadhesive i (40) Tube ID = 10 mm
2 2 Load (kN) Strain Exp Δl (mm) The Δl (mm) Rel. Error
1 0,000365 0,025541852 0,01198
Using once again solid mechanics one can correlate the 3 0,001095 0,076625556 0,03593 53%
5 0,001824 0,127709261 0,05989
shear strain with the shear stress and compute the
displacement of the bonded joint.
As can be seen the error is large and conclusions can
be tough to draw. In part because only the
displacement of the machine’s crosshead and the load
exerted are measured. This makes it impossible to
separate the deformation of the carbon tube from the
deformation of the bonded joint. Volkersen’s theory is
fairly old but can be hold accountable to some extent to
Figure 19 - Unit volume of adhesive in shear treat bonded joints. The problem with this and almost
every theory is that surface condition can’t be
ladhesive tan( ) hadhesive (41) accounted for when doing the calculations. Also
because of the manufacturing process of the specimens,
adhesive the specific bondline thickness cannot be totally
tan( ) (42) guaranteed, in part because of machining imprecisions,
Gadhesive
the tube manufacturing which presents an imperfect
The stress is taken at the extremities of the bonded inner surface and also the increase in thickness due to
joint because that’s the relevant deformation for manual sanding of the surfaces during the surface
elongation analysis of the suspension link. For the preparation stage. All this contributes to the increase of
computation of the CFRP tube elongation one can use bondline thickness that can alter the results of the
equation (37) making sure to use the equivalent physical test. Looking at (41), one can see that an
longitudinal elasticity modulus of the fiber used. This increase in bondline thickness increases the distortion
said one finally computes the suspension link angle. Even though the stresses are lower, this fact
elongation in the following way: can’t prevent the distortion from rising. Since the error
is calculated to the full extent of the specimen and the
llink lCFRP 2 ladhesive (43) deformation of the tube and the adhesive cannot be
separated the decision was to take the error and apply it
to the theoretical value, this means considering the
Since for the design of the FST 05e physical testing
error as a multiplication factor to (43).
was done to ensure that the adhesive joints were able to
sustain the expected loads, these tests were analyzed in
lexp ltheoretical
this work in order to establish a better deformation ER (44)
model. lexp
lCFRP 2 ladhesive
llink (45)
1 ER
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The deformation calculation employs the models of the To simulate the vehicle in the Skid Pad and extract a
compliant components described earlier and has the time around one circumference only one lap is
computation progress shown below: completed.
SW * SW (46)
Figure 22 - Skid Pad layout (FSAE rules) Figure 25 - Front right wheel links compliances
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As one can see, the displacement of the most loaded notable variables between the two simulations can be
link is around 0.45 mm in compression. These seen.
compliances cause the inclination angle of the wheels
to change from the nominal values of the rigid 7 CONCLUSIONS
simulation. Below, is shown the inclination angles of
all wheels: The objective of building a vehicle model
contemplating compliant components was fulfilled.
The vehicle model was developed and the
methodology for the inclusion of compliant
components was exposed. As can be seen from the
results in Table 4, the result of the inclusion of
compliant components was a small difference in
elapsed time due to small changes in trajectory. This
difference is not very significant and the conclusion is
that the modeled compliant components may not have
a very preponderant influence in the FST 05e behavior
around the Skid Pad. This may not be true for other
simulations or with the future inclusion of more
Figure 26 - IA during Skid Pad simulation compliant components, but this is not the mainly intent
of this work.
As seen in the figures above, the trajectory suffers a
considerable change from the rigid model simulation One must notice that the rigid model simulation of the
and the vehicle’s acceleration is also reduced, even Skid Pad is a best case scenario in terms of elapsed
though it begins to increase as the simulation goes on. time. This event requires more driving skills than the
acceleration event and the inputs in the model are
ideally set at the start of the simulation. One should
expect a lower performance from the real FST 05e,
depending on the driver and track conditions but for
comparison purposes the simulation is valid. It must be
noted from the simulations that even though the driver
inputs were held constant for purposes of comparison,
the small changes in trajectory and velocity could
Figure 27 - Path radius and radial acceleration cause the driver to change the inputs so the elapsed
times could have a larger difference if a Skid Pad
Table 2 - Skid Pad comparisons simulation with a real driver was performed.
Rigid Model Compliant Model Validation of results with further physical testing,
Maximum radial preferably with an instrumented FST 05e, would have
1.796 G 1.790 G
acceleration been helpful and it is certainly the missing piece of this
4.722 s Elapsed Time 4.735 work. Besides that fact, this work can contribute to the
design process of the next prototypes for Projecto FST
Novabase and serve as a building ground for further
All the changes shown above capitalize into a slower improvements in vehicle dynamics simulation
time around the Skid Pad even if by not a big performed by the team.
difference. In Table 2 the comparisons of the most
8 REFERENCES
Adams, R. D., J. Comyn and W. C. Wake (1996). Structural Adhesive Joints in Engineering.
Beer, F. P., E. R. Johnston and W. E. Clausen (2006). Mecânica Vectorial para Engenheiros: Dinâmica.
Beer, F. P., E. R. J. Jr., J. DeWolf and D. Mazurek (2011). Mechanics of Materials.
Neves, T. V. (2012). Numerical Model for Dynamic Handling of Competition Vehicles. Masters in Mechanical
Engineering, Universidade Técnica de Lisboa.
Pacejka, H. B. (2005). Tyre and Vehicle Dynamics.
SAE (2008). Vehicle Dynamics Terminology - J670: 73.
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