FSAE 2022 -Aerodynamics Package Upgrade
Introduction
In Formula SAE (FSAE) racing, aerodynamics play a pivotal role, profoundly influencing the performance and efficiency of formula-style vehicles. Effective aerodynamics contribute to higher speeds, improved handling, and enhanced stability on the track, ultimately optimizing fuel economy. The generation of downforce through elements like wings and diffusers not only enhances traction for better control, especially in high-speed turns but also ensures vehicle safety by preventing lift and reducing accident risks. Within the competitive landscape of FSAE, well-tuned aerodynamic designs provide teams with a significant edge, impacting scores in various performance events. This strategic focus on aerodynamics, including the management of unsprung aerodynamics around components like wheels and brakes, enhances overall vehicle stability and handling. Moreover, involvement in aerodynamics offers students a valuable educational experience, allowing them to apply theoretical knowledge to real-world applications and gain insights into the multidisciplinary nature of automotive design, encompassing safety, efficiency, and performance considerations.
The goal for the 2022 competition was to upgrade the 2021 Andromeda V1 race car with a new aerodynamics package and suspension components, directly connecting the aerodynamic elements to the suspension and avoiding attachment to the chassis, thus improving the car's stability and handling during competition.
Andromeda V2
At the start of the design process, the focus was on crafting the aerodynamic components for both the rear and front wings. The downforce generated through comprehensive simulations played a crucial role in shaping and refining the components directly linked to the uprights. While there were supplementary elements affixed to the chassis, the primary objective was to optimize the transfer of downforce generated during vehicle operation. To achieve this, special attention was given to ensuring that the maximum load was intended to be borne by the components directly attached to the uprights. This strategic approach aimed to enhance the overall aerodynamic efficiency and performance of the vehicle, laying a solid foundation for its design and functionality. The images below showcase the suspension components that are the focus of this project.
Front and Rear Suspension attached to the chassis
Rear Suspension
Front Suspension
Rear Upright Brackets
After establishing the downforce values for the rear wing, the subsequent step involved attaching the wing to the car's upright. To ensure proper integration, various angles of the suspension were carefully measured, aiming to understand the suspension's travel relative to the chassis. These measurements played a pivotal role in shaping and determining the loads on the bracket, which bears the highest force during driving conditions. In the intricate process of designing this critical bracket and as part of a graduate optimization project, a detailed report was created. This report delves into the considerations and methodologies involved in optimizing the shape of the bracket through different optimization techniques, ensuring not only structural integrity but also enhanced performance under dynamic driving conditions. Following the recommendations for future work in the report and after comparing different designs, the picture below shows the final design of the bracket used during the 2022 competition.
