FSU-03 Upright V9.2

The Upright

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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

Fixtures

Mesh Refinement

Mesh Size	Location
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 #2: Forwards Left

Node Size	Max Stress (Pa)	Location
7 mm	2.203e+08
6 mm	2.934e+08
5 mm	3.217e+08
4 mm	3.433e+08
3 mm	5.307e+08
2 mm	5.307e+08	More pics

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
6 mm	3.043e+08
5 mm	3.325e+08
4 mm	3.552e+08
3 mm	5.482e+08
2 mm	5.484e+08	More pics

Case #4: Forwards Right

Node Size	Max Stress (Pa)	Location
6 mm	1.372e+09
5 mm	7.216e+08
4 mm	1.363e+09
3 mm	9.551e+08
2 mm	9.522e+08	More pics

Case #5: Forwards Left

Node Size	Max Stress (Pa)	Location
6 mm	6.553e+08
5 mm	6.553e+08
4 mm	5.346e+08
3 mm	4.546e+08	More Pics
2 mm	4.555e+08

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).