ENGS 89/90 Reports

Year of Graduation

2025

Project Advisor

Ryan Halter

Instructor

Solomon Diamond

Document Type

Report

Publication Date

2025

Abstract

Dartnouth Formula Racing placed 12th in the 2024 Formula Hybrid-Electric (FH+E) competition. An updated suspension system is required to improve the acceleration and handling for the 2025 car in order to place higher. To achieve this, the rim size will be reduced from 13’’ to 10’’, camber adjustability will be incorporated into the uprights, and a front anti-roll bar will be added. Using Susprog 3D and kinematic analysis, chassis pickup points and linkage geometry were optimized for the 10” wheels. The full vertical travel and steering behavior of the wheels was analyzed. Designs were developed for the uprights, brake rotors, control arms, rocker arms, steering arms, and push rods to fit the smaller rims. The uprights feature a bolt-on lower ball joint and steering rod assembly with removable plates, enabling efficient camber adjustment without the need to reset toe alignment. The front upright allows for negative 0 to 2.36 degrees of camber adjustment, while the rear provides negative 0 to 3.12 degrees. FEA analysis and thermal simulations under worst-case scenarios confirmed that the braking system can lock all four wheels. Under simulation of realistic conditions, all parts achieved a FOS above 2, and under worst-case conditions, all achieved a FOS above 1. All components comply with FH+E and FSAE regulations and are manufacturable in-house. The new suspension system reduces the car’s weight by 10.7 kg, is estimated to increase maximum acceleration by 0.3 m/s², and should save about 1 MJ of energy during the endurance race. These improvements are expected to enhance lap times and achieve significant energy savings in competition.

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