DESIGN PROJECT

DESIGN OF HALF SHAFT AND REAR WHEEL HUB ASSEMBLY OF A RACE CAR
Faculty co-ordinator: Prof. Gokul Kumar

Design project guide: Prof. B . K Jha

Manvendra Singh Inaniya(08BME126) 9047288146 Ravi Shekhar (08BME181) 9566810725

INTRODUCTION

Project Objective
It was required to design a hub assembly and halfshafts for the Formula 1 car of mass about 640 kg, maximum speed of 300 km/hr and average speed of 150km/hr. The assembly must give stability during rotation of the wheels. The weight and the dimension of the hub must be as small as possible because of the unsprung weight which further reduces the rotational mass. The half-shafts should not fail under stress.

Red Bull RB7 Formula 1 Car

RB7 F1 is the official car from World Champions Red Bull for the 2011 season of Formula 1. We have considered this vehicle as a reference for this Design Project as it is one of the fastest and most technologically matured vehicle in the racing scenario.

Half - Shafts
A half - shaft is an axle on a front wheel drive vehicle connecting the transmission to the driven wheels. The rear wheel driven Formula 1 vehicle being observed for the project uses half shafts in rear, as the differential is rigidly mounted and an independent rear suspension is used.

Design Consideration
Half shafts are designed as
a hollow metal tube to reduce weight. CV joint at either end, allowing the driven wheels to maintain constant velocity . Splines to transmit power between differential, CV joints, shaft and wheel hub. the suspension travels during driving. fatigues due to high speed rotation.

Wheel-Hub
A hub assembly contains the wheel bearing, and the hub to mount the wheel to vehicle. It is located between the brake rotors and axle.

Design Consideration
The bolt pattern is determined by the number of bolts on the wheel hub. Selection of material strong enough to take the weight of the car. Wheel bearings in the hub depending on ID and OD of spindle coming out of hub. Type of lug nuts or bolts.

LITERATURE REVIEW

DESIGN CRITERIA AND DURABILITY APPROVAL OF WHEEL HUB

SAE international,USA 11-16-1998 technical paper authors : Gerhard fischer , Vatroslov V. grubisic The author says that the design of wheel hub must be based on stress generated under customer usage through operational loads acting on wheels. Wheel hub are highly steered safety components which must not fail under the applied loading conditions. The main parameters for design of wheel hub assembly are loading conditions , manufacturing process and material behavior. The influence of these parameters are interactive so material fatigue behaviour will be changed depending upon the wheel hub design and loading conditions.

FRACTURE ANALYSIS OF WHEEL HUB FABRICATED FROM PRESSURE DIE ALUMINIUM ASSEMBLY
theoretical and applied fracture mechanics ,vol 9 feb 1988 authors : S . Dhar
The author says that a catastrophic failure of wheel hub occurred during service. The nature of crack was a corner crack. An analytical investigation was carried out using tool of linear elastic fracture mechanics to establish the cause of failure. The non linear behavior is due to the presence of material inhomogeneties and discontinuities. An analytical estimation was carried out in order to calculate the minimum no. of cycles carried by wheel hub in service. The initiation of crack growth is complex because the heterogeneity and morphology of fracture surface. Fractographic and metallographic studies are carried out to assist the understanding of corner cracking problem.

Finite element modeling of dynamic impact and cornering fatigue of cast aluminum and forged magnesium road wheels.
Proquest dissertation and thesis authors : Shang, Shixian (Robert) 2006 The author says that numerical investigation of wheel dynamics impact and cornering fatigue performance is essential to shorten design time , enhance mechanism performance and lower development costs. The desertion focused on two objectives: i) Finite element models of a dynamic impact test on wheel and tire assembly were developed which considered the material in homogeneity of wheels. Comparison of numerical predictions with experimental measurements of wheel impact indicated 20% reduction of initial striker kinetic energy provide an effective method for simplifying modeling. ii) numerical prediction of wheel cornering fatigue testing was considered. It proceeded in two methods, first was static stress analysis with bending direction applied to the hub. Second was dynamic stress analysis with application of a rotating bending moment applied to hub.

PRELIMINARY PRODUCT DESIGN

Prototype CAD Model Half - Shaft

Isometric View

Parameters for Half-shaft

L Do Di T J G Length of shaft Outer diameter of shaft Internal diameter of shaft Maximum Torque applied by differential on shaft Maximum Normal Stress on shaft Maximum Sheer Stress on shaft Polar Moment of Inertia of shaft Modulus of Rigidity

Wheel Hub

Parameters of Wheel Hub

n b d S W P Number of Bolts Bolt Circle Diameter or Pitch Circle Diameter Flange diameter is measured between opposite holes Spoke hole diameter Width centre to flange Load capacity is the amount of weight a wheel will carry

THEORETICAL DESIGN

Half - Shaft
GIVEN :
Maximum Torque of engine at 14000 rpm = Gear ratio for 1st gear Final Drive ratio 280 N-m = 1.833 = 2.15

Material selection:

The material chosen for the design of Half shaft is ion nitrided titanium alloy. The titanium and titanium alloys have unique corrosion, nonmagnetic and strength to-weight ratio properties. Mechanical properties of nitride titanium alloys are as follows: Yield stress = 1.24105631 109 Pascal Maximum Sheer Stress = 0.62052815 109 Pascal

Calculation of Torque at half-shafts:

Shock torque = factor of safety x first gear ratio x final drive x maximum engine torque = 2.5 x 1.833 x 2.15 x 280 = 2758.665 N-m. Internal to external diameter ratio, k = 5 As T = 6246.765 N-m , = 0.62052815 109 Pascal , k = 5 The Axial Force acting upon the half-shafts has been countered by adding plunge to the C.V. joints at the end of the half-shafts The Gyroscopic couple acting due to rotational masses likes tyres, camshafts and crankshafts is negligible as the rims, camshafts and crankshafts are made of light weight titanium alloys which contribute insignificantly to gyroscopic couple. No bending moment is observed as no additional weight, except self-weight of halfshafts, is loaded on the half-shafts. Thus our calculations would be based upon the strength required from shaft under torsional loading only.

= (/16) x x (do)3 x [ 1 (di / do)4] We have, k = di / do = 5

So, 2758.665 = (3.14/16) x 0.62x 109 x (do)3 [ 1 (1/5)4] do3 = 22882.115

do = 28.39 mm Or, do = 29 mm. Therefore, di = 29/5 di = 5.66 mm. From the design calculation we find that the required external and internal diameter of the half shaft as per the specified engine parameters and given conditions is 29 mm and 5.6 mm.

Wheel-Hub Assembly
Tires and rims selection:
The tires selected were of 13 diameter. The diameter was selected as such that floor of the formula car does not touch the ground. At the same time a low ride height would give an aerodynamic as well as low Centerof-gravity advantage. Number of bolts is taken 4 as it is a standard for 13 wheels. Pitch Circle Diameter(P.C.D.) is fixed at 100 mm as it is a standard for 13 wheels. Spoke Hole Diameter(S) is taken as M12 as it is a standard for 13 wheels. Material : Ti6Al4V - titanium alloy is the most widely used .

Brake Force Calculation

Brake force is required to estimate the load on the wheel hub. As almost all the design parameters of a wheel hub are fixed by the size of wheel, the thickness of the wheel hub is the defining parameter. The thickness of wheel hub is determined by maximum force acting on a wheel.

Brake Calculation

:-

Velocity of Vehicle Frictional force will be acting on it Stopping distance

= = =

vo F d

Friction force of the road must do enough work on the car to reduce its kinetic energy to zero . To reduce the kinetic energy to zero Workfriction = mgd = 0.5mv02 d= vo2/2g Velocity of our vehicle Friction of road d = = = 150 km/hr 0.90 98.31 m

Acceleration of the vehicle:-

vo2

= u2 + 2ad

Where a is the acceleration of the vehicle a = vo2/2d a = 8.8m/s Total force acting on the vehicle Ftotal = mv* a Where mv is the mass of the vehicle = 640kg Ftotal = 640 * 8.8 = 5632N Force on each wheel:F1 = Ftotal/4 = 3953.43/4 =1408 N F1 = 1408 N

Torque on the tire:Tr = F1 * rtire Rim is taken to be 13 rtire = 20.43 * 0.0254/2 Tr = 1408 * 0.2595 Torque on disc:Tdisc = Ffriction*reffective

= =

0.2595 m 365.35 N-m

disc is assumed to be 200mm , therefore reffective should be 9cm we know that Tdisc = Ttire Ffriction Ffriction = = 25647.012 / 9 2849.67N

Force on the clamp:Fclamp = Ffriction/ = 2849.67/0.5 = 5699.34 N

SOFTWARE ANALYSIS

Wheel Hub Assembly

In design stage, we estimated all the forces acting on hub and disc The wheel hub was modeled in CAD with given parameters The forces were applied on model using Finite Element Analysis in ..COSMOS The thickness of hub was varied in increments of 2 mm till a Factor ..of Safety value of 2 was attained Thus the final design of wheel hub is complete

Finite Element Analysis

No external force External force applied

Factor of Safety = 2

Safe Design

DETAILED PRODUCT DESIGN

Half - Shaft
Material = ion nitride titanium alloy Yield stress = 1.241 x 109 Pascal Max. Shear stress = 0.62 x 109 Pascal Engine characteristics N = 1400 rpm T = 280 N-m. First gear ratio = 2.833 Final drive ratio = 2.15 Shock torque = 2758.665 N-m. K, d0/di =5 External dia. = 29 mm. Internal dia. = 5.6 mm

Wheel hub
Tyre dia. No. of bolts Pitch circle dia. Spoke hole dia . Material Stopping distance Velocity of vehicle Acceleration of vehicle Force on each wheel Torque on tyre (R-13) Diameter of disc Effective radius Clamping force Width of flange = 13 =4 = 100mm. = M12 = Ti6Al4V titanium alloy = 98.31 m. = 150 Km/hr. = 8.8 m/s2. = 1408 N. = 388.75 N-m. = 200 mm. = 90 mm. = 8638.86 N. = 10 mm.

conclusion
Wheel Hub has been designed for a formula 1 car of mass about 640 kg, maximum speed of 300 km/hr and average speed of 150 km/hr. The designed assembly gives stability during rotation of the wheels.

The weight and dimension of the hub is such that it reduces the rotational mass. The design project enabled us to understand the various forces that act on a half shaft and wheel hub, while the Formula 1 race car is in running condition. The calculated parameters help us to design half - shaft and wheel hub such. The design project helped to better under the uses of software in real scenario.

GANTT CHART(Design Project) "DESIGN OF HALF - SHAFT OF A PROTOTYPE RACE CAR" Time in Weeks Sl No. CATEGORY 1 2 3 4 5 6 7 8 9 Topic and guide selection A for project B Literature review Develop preliminary C product design D Theoretical Design E CAD modelling F Software analysis G Optimization of design Develop detailed product H design Final Presentation I Compilation ***Please note that the weeks mentioned above doesnot contain the CAT weeks.

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THANK YOU