Redesign of Lotus Europa Front Suspension

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Redesign of Lotus Europa Front Suspension

• ME 450 Finite Element Analysis
• Spring 2007
• Presented by
• Bart Sudhoff, Zachary Lightner, Jim Milligan,
  Brian Schludecker, David Giles
• Dr. Nema
• 4/30/2007

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Summary Introduction

• Redesign Front Suspension Upper Control Arm
• Top Speed Increase 120 to 200 MPH
• Design Issues
• New weight of car due to increased engine size
• New handling characteristics

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Original Design

• Built in 1970
• 1470cc OHV 4 Cylinder Engine 78HP
• Front Wheel Drive
• 4-Speed Transmission
• Curb Weight 1320-1570lbs
• Top Speed 120 MPH

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New Design

• Engine Lexus V8 4.0L Quad Cam
• Transmission Porsche 5-Speed
• Suspension New Design of Lower/Upper Control
  Arms, Springs, Shocks
• Factor of Safety of 5
• Light Weight
• Minimal Deformation

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Theoretical Background

• Decomposition of model into stiffness, force
  matrices
• Solution in form of nodal displacement matrix
• 4-node tetrahedral element displacement solution

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Model Details

• Upper and Lower Control arms modeled using Pro/E
• Constraints
• Fix about the mounting holes
• Forces applied at ball joint

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Model Details
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Model Details
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Model Details
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Results

• 2 thick arm
• Stress - 20.06 MPa
• Deformation - .102 mm
• Safety Factor Greater than 10

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Results

• 1.75 thick arm
• Stress - 25.1 MPa
• Deformation - .128 mm
• Safety Factor Greater than 5

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Results

• 1.75 thick arm with relief
• Stress - 18.9 MPa.
• Deformation - .131 mm
• Safety Factor Greater than 5

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Results

• 1.5 thick arm with relief
• Stress - 24.4 MPa
• Deformation - .184 mm
• Safety Factor Greater than 5

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Results

• 1.5 thick arm with relief
• Vertical Bump
• Stress - 3.82 MPa
• Deformation - .0229mm
• Safety Factor Greater than 10
• Rebound
• Stress - 14 MPa
• Deformation - .106mm.
• Safety Factor Greater than 10

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Conclusion

• Chose 1 ½ control arm with relief cuts
• Passed factor of safety tests
• has allowable deformation
• Will allow car to go 200 mph