Optimization of a composite-based belleville spring system for racing vehicles

Abstract

Motorsports has a critical role in the application of new technologies developed by engineers for the automotive industry. Issues such as weight reduction studies, products with new types of materials, and the implementation of different designs are extremely important to win a race. Composites are materials that are created by blending two or more natural or synthetic elements (with various physical or chemical qualities) to create a new material that is stronger than the sum of its parts. The constituent parts merge and contribute their most advantageous features to enhance the result or finished product, but they do not totally blend or lose their own identities. Composites are frequently created with a specific purpose in mind, such as increased durability, efficiency, or strength. The designer must consider and calculate material specifications and combinations, enviromental conditions, maximum stress and deflection results of the system. The suspension system is a group of components that connect the wheels of the car together and work to maintain the highest levels of comfort, driving safety, and road holding under all types of braking and unexpected directional changes. It has traditionally served two purposes: ensuring the safety of the vehicle's handling and braking, and protecting passengers from vibrations and other influences. The suspension of a wheeled vehicle is a mechanical system of springs or shock absorbers connecting the wheels and axles to the chassis. Springs have important characteristics such as geometry, material and assembly type. In this study, the most commonly used springs in racing and automotive industry were investigated in order to design a composite-based Belleville disc spring. Design development was supported with a combination of previous works and feasibility studies. Optimization studies were then conducted for finding the most efficient, lightweight and adjustable disc spring. Results showed that Belleville disc springs are a very realistic alternative to steel helical coil springs with variety of designs, good material properties and a decreased weight of the system without any compromise.