College - Author 1
College of Engineering
Department - Author 1
Mechanical Engineering Department
Degree Name - Author 1
BS in Mechanical Engineering
College - Author 2
College of Engineering
Department - Author 2
Mechanical Engineering Department
Degree - Author 2
BS in Mechanical Engineering
College - Author 3
College of Engineering
Department - Author 3
Mechanical Engineering Department
Degree - Author 3
BS in Mechanical Engineering
Date
3-2021
Primary Advisor
John Fabijanic, College of Engineering, Mechanical Engineering Department
Abstract/Summary
Our team has been tasked with optimizing hardpoints for the Cal Poly Racing team. Hardpoints are the locations on the chassis of a car that are designed to carry both internal and external loads, they are the areas where the engine and suspension connect to the chassis. These points are subject to torsion, shear, bending and pull-out loads. Cal Poly Racing needs more thoroughly analyzed individualized hardpoints that are optimized for weight, strength and specific stiffness, so they can reduce the overall weight and improve the race times of the vehicle while maintaining their strength and stiffness standards. Our team has reviewed past projects, research papers, and test results to gain a strong understanding of hardpoints. Our goal was to design a hardpoint that minimizes weight while maintaining the strength and stiffness standards of Cal Poly FSAE. After changing our point of contact on the team and learning about the cancelation of a physical race car during the course of the project the design scope changed. Designing hardpoints for specified loads became less important, as the loads had become obsolete. More importance was placed on testing materials and acquiring data. Specifications were added, including designing a jig for multiple tests to be run on hardpoints and testing expired laminates to get more accurate test data, as the original datasheets aren’t accurate. We created a final hardpoint design that will need to be tested in the future. The material choices made are listed in the report, as well as testing data for laminates we obtained. Additionally, since our sponsor no longer had a suitable jig to test hardpoints inlaid into sandwich panels, we designed a new jig that would be used to test hardpoints and validate the design choices made.The jig has the ability to hold 10”x12”x1” sandwich panels at various angles and both shear and pullout tests. Our jig was designed using beam stress analysis and computer aided finite element analysis. Finally, the recommended tests and analysis for picking the final hardpoints is addressed. Shear and pullout tests at different angles must be performed to determine core puck size and insert choice. Insert and potting radius sizing will likely have to be reiterated after testing to produce the ideal final hardpoint design.
URL: https://digitalcommons.calpoly.edu/mesp/579