Fatigue Analysis and Optimization of Upright of a FSAE Vehicle

Formula racing car components experience immense mechanical loads which keep varying all through the life span of the components. It is essential to know the life of a component and replace it in time to ensure performance, reliability and durability of the vehicle. This paper addresses the fatigue life analysis of the Uprights for a Formula SAE vehicle and optimization of the design based on the results to increase the life. The front and rear uprights have been designed using the 3D modeling software CATIA and in accordance to the formula SAE rulebook 2018. The analysis parameters are derived from the logics and simulations of the vehicle design parameters using Optimum Dynamics. The study covers both static and fatigue analysis of the components with their respective boundary conditions and the analysis software used to carry out the static and fatigue analysis are Ansys Workbench and Ansys nCode respectively. A comparison on the results obtained from the static analysis and fatigue analysis is made and benefits of fatigue analysis over static analysis are shown.