DESIGN AND ANALYSIS OF A 10” CARBON FIBER WHEEL FOR A FORMULA SAE RACECAR

Abstract

Formula SAE is an engineering design competition for students where the goal is to design, build, and compete a Formula-style single seater race vehicle. With a legacy dating back to 1982, UTA Racing has been one of the most competitive teams. In this project, a carbon fiber 10” wheel is designed for the first time, achieving reduced unsprung weight and lower rotational inertia, both of which are key performance characteristics in vehicle dynamics. The design follows Tire and Rim Association guidelines to ensure dimensional compatibility and ease of assembly and is analyzed for 2G cornering with 3G bump. The simulations were executed for 16 configurations based on a parametric design. The project also includes the design and analysis of a modular wheel mold that allows for possibility to manufacture several wheels with varying, width, locking mechanism and weight reduction patterns for future design changes. The wheel design selected for manufacturing is compared for factor of safety, weight and wheel deflection with the other configurations. This wheel is estimated to weigh 1.8 lbs, demonstrating 29% weight reduction on the existing 10” carbon fiber-aluminum wheel assembly.