The Upright
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Model Version: 8.0 Material: 7075 T6 Yield Strength: 5.03e+08 Validation: June 15th, 2023 - By: Katherine Nguyen |
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Loading
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Loading Case #1:
Spindle to Upright | 0 | 2096.57 | 0 | 0 | 0 | 87.3221405 |
Loading Case #2:
Spindle to Upright | -1080.4 | 2160.8 | 1080.4 | 0 | -48.261468 | -211.65036 |
Loading Case #3:
Spindle to Upright | 759.92 | 1519.85 | 759.92 | 0 | -29.3557096 | 275.4714165 |
Loading Case #4:
Spindle to Upright | -1381.27 | 2762.55 | -1381.27 | 0 | 53.3584601 | -270.5903765 |
Loading Case #5:
Spindle to Upright | 971.55 | 1943.1 | -971.55 | 0 | 43.3991385 | 352.186875 |
Interactions
Assembly consists of:
Upright
Upper upright bearing cap (from FSU)
Lower upright bearing cap (from FSU)
Dummy bearing housing (1 in upper and 1 in lower)(part made from GEH 12 C)
Dummy bolts (6 in upper & 6 in lower) (part made for simulation)
Component Interactions
Global interactions set to contact.
Local Interactions
Bolts and Bearing Caps
Bonded for the upper and lower bearing caps to inhibit the Z translation of the pieces
Bolts and Upright
Bonded for the upper and lower upright to inhibit the Z translation of the pieces
Fixtures
Mesh Refinement
Mesh InfoSize | Location |
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2.00 mm element size; 1.80 mm min |    |
1.00 mm element size; 0.9 mm min |  |
0.3 mm element size; 0.27 mm min |  |
2.10 mm element size; 1.89 mm min |           |
3 mm element size; 2.7 mm min |   |
Mesh Convergence & Results
Case
#1#2:
RestForwards Left
Node Size | Max Stress (Pa) | Location |
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Case #2: Forwards Left
Node Size | Max Stress | Location | |||||
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4 mm |
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3.5 mm |
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3 mm |
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2.5 mm |
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2 mm |
| 7 mm | 2.203e+08 |
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6 mm | 2.934e+08 |
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5 mm | 3.217e+08 |
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4 mm | 3.433e+08 |
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3 mm | 5.307e+08 |
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2 mm | 5.307e+08 | 
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Weird jump from 4mm node to 3mm node, but fails at the steering arm attachment point.
Case #3: Backwards Left
Node Size | Max Stress (Pa) | Location | |||||
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4 mm6 mm | 3.043e+08 |
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5 mm | 3.5 mm325e+08 | 
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4 mm | 3 mm.552e+08 |
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3 mm | 5.482e+08 |
 | 2 mm |
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2 mm | 5.484e+08 | 
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Case #4: Forwards Right
Node Size | Max Stress (Pa) | Location | |||||
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4 mm6 mm | 1.372e+09 |
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3.5 mm | 7.216e+08 |
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3 mm4 mm | 1.363e+09 |
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3 mm 2.5 | mm 9.551e+08 |
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2 2 mm | 9.522e+08 |
 
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Case #5: Forwards Left
Node Size | Max Stress (Pa) | Location | |||
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4 6 mm |
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| 3.5 mm | 6.553e+08 |   |
5 mm | 6.553e+08 |  
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3 4 mm | 5.346e+08 |
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3 mm 2.5 | mm 4.546e+08 |
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2 mm |
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2 mm | 4.555e+08 |
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Recommendations
The upright is failing in all cases at the attachment points to the steering arm. The first place it fails is at the virtual wall between the face of the upright and the steering arm. I would suggest making the attachment surface area between the upright and the steering larger (ex. by adding more bolt holes or spreading the bolt holes more widely across the upright).
The second place it fails is at the corner of the crevice where the steering arm meets the upright and prevents it from twisting. I would suggest a fillet at the sharp corners to distribute the load more evenly (as shown in red below).
