Lightweight is a primary focus within the motorsport industry.
"Adding power makes you faster on the straights. Subtracting weight makes you faster everywhere" - Colin Chapman.
Removing weight in the suspension is both challenging and rewarding. Challenging because suspension systems are heavy loaded systems, rewarding because removing weight here will improve both the total vehicle weight and improve the sprung/unsprung ratio.
Suspension uprights are a typical product where performance can be gained by reducing weight and increasing stiffness.
The Objective
Fransiscó was asked to lead the development of a lightweight upright for a Lotus Elise Series 1.
The redesigned upright should:
Lower the ride height while maintaining the suspension kinematics
Withstand severe motorsport loadcases
Extreme braking forces
Over 2g cornering loads
Curbstone impacts in lateral, vertical and longitudinal directions
Increase the camber stiffness compared to the OEM upright
Achieve a weight reduction of 25% or more
Be flexible in terms of bearing use and bearing position
Facilitate camber adjustments
The intended production method is Metal Additive Manufacturing. The geometry should be designed accordingly.
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