Purpose
The Vehicle Dynamics Subsystem is the broadest subsystem. At the core of operations lies 4 pillars:, steering, suspension, brakes and wheels, each demanding a unique blend of expertise and hands-on manufacturing finesse.
Goals
| Primary Goals |
|---|
| Design and manufacture new suspension system |
| Design and manufacture new steering system |
| Secondary Goal |
|---|
| Weight optimisation |
| Improve car dynamics through adjustable components |
Key Components
Suspension System
The suspension system in an FSAE car is a critical component designed to optimize handling, stability, and ride comfort. In MUR Motorsports, the suspension system is meticulously developed to ensure the car can navigate tight corners and handle dynamic loads effectively during competition. It involves a complex arrangement of components to absorb shocks and maintain tire contact with the road surface.
Our journey in suspension design spans from software-driven geometry planning using SusProg to CAD modelling using Fusion 360. Then through FEA, we ensure stress-resistant linkages are crafted from profiled chrome-moly tubing. Finally, the suspension will be assembled onto the chassis. Collaboration with chassis subsystem is also needed to ensure all mounting is accurate and available.
Brake System
Engineering a high-performance brake system requires practical designs of brake cylinders, lines, callipers, and rotors. These components are first designed in CAD, and the lines are custom cut and fitted to the chassis. The brake rotors are also custom designed, analysed in FEA to ensure sufficient strength and cooling characteristics, and then made from waterjet cut cast iron plates. Collaboration with ergonomics subsystem is required for the pedal box designs.
Wheels and Outboards
Our focus is selecting the right tyres and rims to place on the most complex part of the car, the outboards. Outboards is the wheel holder to put it simply, connecting the suspension and steering components to the wheels of a vehicle. They serve as the intermediary structure, facilitating the transmission of forces and movements to the wheels.
Steering System
The steering system in an FSAE car is a vital component for precise control and handling. In MUR Motorsports, the steering system is carefully designed to provide the driver with responsive and accurate direction control, especially during high-speed maneuvers. The system includes key components such as the steering rack, tie rods, and linkages, which must be robust yet lightweight to maintain performance.
Future Research Projects
Future projects in the Vehicle Dynamics subsystem of MUR Motorsports aim to enhance the car’s handling and performance through innovative materials and design improvements. One key focus is ongoing work in refining suspension geometry, using advanced simulation tools to maximise tyre contact and optimise grip in various driving conditions. Further weight optimisation of existing components can utilise topology optimisation and finite element analysis to reduce weight without sacrificing performance. A potential project is the development of carbon fibre suspension components, which would reduce the weight of the car while maintaining strength and rigidity, leading to better agility and speed. Another project would involve creating a carbon fibre steering system to further optimise weight reduction and improve control. These projects will help push the limits of vehicle dynamics, improving overall performance and competitiveness on the track.
Industry and Work Opportunities
Working in the Vehicle Dynamics subsystem offers excellent opportunities in the automotive industry, particularly in high-performance and electric vehicles (EVs), as well as motorsports, where precision in handling is key. Skills in suspension, steering, and braking systems are crucial for roles like Vehicle Dynamics Engineer, Suspension Engineer, and Braking System Engineer, and are also applicable in aerospace and motorcycle design. Additionally, there are exciting careers in motorsports as a Race Engineer, where vehicle dynamics knowledge is essential for optimizing race performance, making real-time adjustments, and enhancing race strategy. These skills are also valuable in systems integration and research and development for autonomous and sustainable transportation technologies.
Materials and Manufacturing Exposure
| Materials |
|---|
| Chrome-moly Steel |
| Aluminium |
| Mild Steel |
| Manufacturing |
|---|
| Milling and Lathing |
| CNC Machining |
| Laser Cutting |
| Water Jet Cutting |
| Welding |