The upper control arm needs to be trimmed to reduce interference with the rims while turning. An experimental cut was made on the UCA assembly to conduct FEA and interference checks with the new steering system.

Sketch of cut and picture of trimmed UCA:

Open

Open

FEA Results:

The fixtures are the same as those described in https://uwmidsun.atlassian.net/wiki/x/F4Chww , excluding the screw holes on the bearing housing.

The loading cases are derived from , calculations by @Jens Dekker. Although the loading cases will be slightly off because the UCA is no longer at the same angle as in the calculations, the results still provide a reasonably accurate idea of the stress concentrations.

Rest:

Acceleration + Right Turn:

Acceleration + Left Turn:

Brake + Right Turn:

Brake + Left Turn:

It can be seen from the FEA results that the maximum stress does not exceed the yield stress and that the stress concentrations are not near the cut areas. Tacks can be applied to the corners for sanity purposes.

Interference Check:

Inner Turn:

There is max 3.2 mm clearance between the rim and the UCA

Outer Turn:

There is a max clearance of 6.29 mm of clearance between the UCA and rim.

As per the cad there does not seem to be any interference with the trimmed UCA and the rim in the new steering system.