A detailed study on design, fabrication, analysis, and testing of the anti-roll bar system for formula student cars

Abstract

This study explains a coherent flow for designing, manufacturing, analyzing, and testing a tunable anti-roll bar system for a formula student racecar. The design process starts with the analytical calculation for roll stiffness using constraining parameters such as CG (Center of Gravity) height, total mass, and weight distribution in conjunction with suspension geometry. Then, the material selection for the design i.e. Aluminum 7075 T6 is made based on parameters such as density and modulus of rigidity. A MATLAB program is used to iterate deflection vs load for different stiffness and shaft diameter values. This is then checked with kinematic deflection values in Solidworks geometry. To validate with the material deflection, finite element analysis is performed on ANSYS workbench. Manufacturing accuracy for the job is checked using both static analysis in lab settings and using sensors on vehicles during on-track testing. The error percentage is found to be 4% between the target stiffness and the one obtained from static testing. Parameters such as moment arm length, shaft diameter and length, and deflection were determined and validated. This paper shows the importance of an anti-roll bar device to tune the roll stiffness of the car without interfering with the ride stiffness.

Enhancing the Stability and Safety of Vehicle When Steering by Using the Active Stabilizer Bar

“…Usually, the stabilizer bar has a symmetrical U-shape. Several other shapes of bars are also used to suit the installation site (Figure 1) [9]. e two ends of the stabilizer bar will attach to the hub of the wheel.…”

Designing Variable Ackerman Steering Geometry for Formula Student Race Car

“…A straight line connecting the tie rod outboard point to the instantaneous center (IC) of the wheel is the domain for the inboard point. The height of the inboard point decides the height of the steering rack, so the decision made is based on the positioning of the steering rack [13,14].…”

Performance Improvement during Attitude Motion of a Vehicle Using Aerodynamic-Surface-Based Anti-Jerk Predictive Controller

“…Leaning the vehicle body against the vehicle body forces during lateral or longitudinal motion is very useful to mitigate the load transfer effects to enhance ride comfort. For example, the authors of [ 44 , 45 ] used an anti-roll bar methodology to reduce the impact of load transfer during cornering. In [ 46 , 47 ], tilting control systems were developed to improve vehicle safety during cornering.…”