1. Designreport Suspension System

2. Structure • Concept and Construction • SIMPACK MBS Model • Rods Designreport Fahrwerk

3. Concept and Construction • multi link suspension system with pullrods • characteristics of the suspension system Designreport Fahrwerk

4. Concept and Construction • multi link suspension system with pullrods • suspension outside of the chassis Designreport Fahrwerk

5. MBS Modell • MBS Tool SIMPACK is used • MBS model of the 2010 car • kinematics of the suspension system • roll and pitch rate • max. forces at joints Designreport Fahrwerk

6. MBS Modell - kinematics of the suspension system • camber to wheel travel front rear Designreport Fahrwerk

7. MBS Modell - kinematics of the suspension system • toe in/toe out to wheel travel front rear Designreport Fahrwerk

8. MBS Modell - kinematics of the suspension system • camber to steering rod travel Designreport Fahrwerk

9. MBS Modell – roll rate • steady state Designreport Fahrwerk

10. MBS Modell – roll rate • camber and roll rate to lateral acceleration • roll rate: 1,9 °/g Designreport Fahrwerk

11. MBS Modell – roll rate • checking lifting of center of gravity → no lifting Designreport Fahrwerk

12. MBS Modell – pitch rate • up to 1,5 g deceleration Designreport Fahrwerk

13. MBS Modell – pitch rate • Pitch rate to deceleration • pitch rate: 1,3 °/g • no lifting of center of gravity Designreport Fahrwerk

14. MBS Modell – max. forces at joints • forces due to cornering (up to 1,5 g) [N] • forces due to deceleration (up to 1,5 g) [N] • forces >0 → pulling • forces >0 → pushing Designreport Fahrwerk

15. MBS Modell – max. forces at joints • forces due to shoks • simulation of an shock due to curbs (100 mm high) with an speed of 100 km/h → worst case Designreport Fahrwerk

16. MBS Modell – max. forces at joints • forces due to shocks[N] • forces >0 → pulling • forces >0 → pushing • approximation of max. forces at joints and rods to 5000 N Designreport Fahrwerk

17. Rods – Construction an concept • CFK tubes with Al Inserts • Joints with M6 left and right threads Designreport Fahrwerk

18. Rods – Construction an concept • CFK tubes with Al Inserts • Joints with M6 left and right threads Mutter M6 - RH Gelenk SAK 6 Carbonrohr Insert RH Mutter M6 - LH Gelenk SALK 6 Insert LH Designreport Fahrwerk

19. Rods - Calculation • calculation of the joint thread Designreport Fahrwerk

20. Rods - Calculation • calculation of the thread of the inserts Designreport Fahrwerk

21. Rods - Calculation • calculation of the tubes, comparison of steel, Al, CFK → 2010 car Designreport Fahrwerk

22. Rods - Calculation • calculation of the tubes, comparison of steel, Al, CFK Designreport Fahrwerk

23. Rods - Calculation • calculation of the adhesive bond Designreport Fahrwerk

24. Rods – Tests of the adhesive bond • tensile tests of some test tubes • Ø 14 mm • Ø 18 mm • two glues • Loctite 9466 A&B • Macroplast UK 1366 B10 • two inserts • 18 mm • 23 mm • one unprepared sample Designreport Fahrwerk

25. Rods – Tests of the adhesive bond • tensile tests Designreport Fahrwerk

26. Rods – Tests of the adhesive bond • tensile tests of some test tubes • Ø 14 mm • Ø 18 mm • two glues • Loctite 9466 A&B • Macroplast UK 1366 B10 • two inserts • 18 mm • 23 mm • one unprepared sample Designreport Fahrwerk

27. Rods – Tests of the adhesive bond • test report Designreport Fahrwerk

28. Rods – Tests of the adhesive bond • test report Designreport Fahrwerk

29. Rods – Tests of the adhesive bond • the thread of the samples 3 and 4 broked at 14000 N • the adhesive bonds are ok Designreport Fahrwerk

30. Rods – Tests of the adhesive bond • samples with macroplast glue were not ok • adhesive bonds of Ø 14 tubes is to weak Sample-ID: 1 2 3 5 7 8 11 no damage of the adhesive bond Designreport Fahrwerk

31. Rods – Interpretation • so we use: • Ø18 mm CFK tubes • 18 mm Al inserts with M6 threads • Loctite 9466 A&B • preparation of the adhesive surfaces • sandblasting • sanding • cleaning Designreport Fahrwerk