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Old 07-04-2013, 04:15 PM   #1
adamskiTNR
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FSAE hub

Thought i'd just share my completed Formula Student conical face hub design now that it's complete for all those who it may interest.

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Old 07-04-2013, 04:31 PM   #2
indigorallye
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Right hand and left hand threads on the hub?
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Old 07-04-2013, 04:36 PM   #3
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?......i did.......lol?

No. This conical face design removes all the fretting forces normally associated with peg drive centrelocks. The wheel nut just provides force closure. So no need.

It is hard to see in this picture how it works. I will try and get another up showing it more clearly. But the mating face between the hub and wheel is made up of 4 conical tapered teeth, locking all directions of freedom with the wheel nut clamping in place

And no, the threads are not modelled, just constrained.

Last edited by adamskiTNR; 07-04-2013 at 04:36 PM. Reason: Automerged Doublepost
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Old 07-04-2013, 07:34 PM   #4
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Nice.

I was in FS in 2009, first team to enter from Aberdeen Uni, probably one of the most worth while things I done at uni!
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Old 07-04-2013, 08:44 PM   #5
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Here's a slightly better image. Older so there are a few changes, but the concept is the same.

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Old 07-04-2013, 09:16 PM   #6
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Very nice! Are you competing in FS?

Gotta love a bit of CAD porn. I specialised in CAD with my degree, made a fully reciprocating V8 with working cams/valves. Lost all the files though, fail. I'm using Seimens NX daily but still prefer SolidWorks.
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Old 07-04-2013, 09:46 PM   #7
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We don't have the funding or the numbers involved to run a team. This is the starting foundation of it hopefully. Got various students going through the design processes of various systems. Hopefully be able to get a team up at some point down the line, but it wont be in my time.
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Old 07-04-2013, 09:59 PM   #8
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We struggled with funding too!

Might sound boring but look into doing an electric one. Saw one at the Greenpower finals at Goodwood. People might be more willing to help you out
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Old 07-04-2013, 10:02 PM   #9
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I'm considering doing some research into electric drive integration for my final year dissertation. It really interests me. And from an engineering point of view the internal combustion engine really has no legs to stand on in comparison. Once energy storage improves everything will be electric. I had a brief look around the toyota e-wolf electric prototype racer, that thing is dangerously fast.
http://www.youtube.com/watch?v=t9GR9EVsk-g
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Old 08-04-2013, 08:51 PM   #10
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Looks good mate! Definitely different as most teams tend to use the conventional 4 stud design with a custom hub setup.

I'm currently in the LJMU team although I specialise in the vehicle dynamics aspect of the car. For my dissertation this year I created a fully parametrised, non-linear multi-body model of our 2012 car within a simulation package (Dymola). I was only able to validate the simulation model to the manufactured car by using both longitudinal and lateral acceleration values from the Sliverstone FS event (specifically the skid pad). I managed to conclude that the model was between 93-98% accurate which everybody seemed amazed with. I then managed to look at the tyre forces, yaw/slip angles and camber/toe/caster changes across the suspension travel but could not validate the simulation results as we had no experimental data for these. We probably never will neither but it definitely allowed a more in depth understanding of the car and further analysis is now being undertaken looking at the chassis stiffness during cornering.

It took me ages to get all of the components of the car in (ended up using over 3000 blocks) to represent every single part of the car. I then had to gather all measurements and enter them into the model. Was the best feeling ever printing off 120 odd pages and binding it together to hand in. Shame I've got to do it all again next year for my Masters although its group work!

This is a quick render / photoshop of my multi-body model that I'm going to use in my viva. The standard simulation model just gives a 3D animation of the car completing a double lane change manoeuvre on a white background so though this looked a little more impressive .

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Old 08-04-2013, 10:10 PM   #11
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Don't think i would have the patience to be a data engineer. My mind would melt after days of numbers.

Here is a better picture of the conical spline on the hub.
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Old 02-05-2013, 09:58 PM   #12
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All finished and rendered.

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Old 04-05-2013, 07:30 PM   #13
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Lovely job! Can't be far off making it for real?
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Old 04-05-2013, 09:04 PM   #14
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Money ....... although i did consider getting an ABS 3d prototype in time for the presentation
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Old 16-05-2013, 12:35 PM   #15
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3D prototype is complete!
Pretty cool to have it in my hands. Smaller than i imagined it lol, despite the numerous scale drawings i have.

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Old 16-05-2013, 02:09 PM   #16
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3D printed too? Looks great.
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Old 16-05-2013, 02:14 PM   #17
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No i whittled these out of wood....... yeah they're printed
By Cadventure London. Big shout out to them, good service. 4 days from email to delivery.
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Old 16-05-2013, 03:39 PM   #18
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The company I work for has a large rapid prototyping department, great for things like this! Naturally it never gets used for home jobs... We have Objet, SLS, and a few others to play with. Makes for some cool lunchtimes.

Well played though looks quality. Any thoughts on careers after Uni?
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Old 16-05-2013, 03:51 PM   #19
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Cheers. Planning to do the obvious route of automotive design engineering. I am doing a motorsport focussed course, but i know the reality of a race team. The guys doing the designing of the race cars at "non-works" teams (e.g.. the majority) are in low numbers, and are usually highly experienced, older engineers. I believe the best route is to go into large corporate automotive engineering offices as an incorporated engineer. Get the experience there before diving into the high responsible world of designing race cars with a few people involved.
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Old 16-05-2013, 03:58 PM   #20
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Very very tough jobs to get. We lost a graduate at work because he was offered a role at Mclaren. Can't say I blame him. We do a lot of work with some high end race teams (inc F1) which can be pretty epic to see!

Good luck to you fella, sounds like you've got your head screwed on at least. If you do manage a race team though don't expect a long career in it, long, tough days away from family for weeks on end etc... A lot of their race mechanics at least are burned out after a few years of doing it.
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Old 16-05-2013, 04:33 PM   #21
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I'm not planning to do mechanic work. Planning to be sitting in a cushty office lol
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Old 21-08-2013, 01:19 PM   #22
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Bored over the summer, So finished the brake bell and disc assembly

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