The document describes the design of a front suspension mount for the Immortus EVX solar car. The design team's goal is to create a mount that is lightweight, strong, and accommodates the needs of the existing suspension system and solar car. Several design iterations are discussed, including designs made of titanium, carbon fiber, or combinations of materials. The current design under consideration is a tubular titanium truss with a carbon fiber core that aims to take advantage of the strengths of both materials. The document outlines the considerations and tradeoffs surrounding material selection, manufacturing techniques, existing knowledge, and the design process.

1. Immortus EVX Solar Car
front suspension mount
Josh Patterson
Jai Cornes
Steve Taylor
Anthony Campana

2. Introduction
 Our design statement
“Design and build the front suspension mount of the Immortus EVX solar car. “

3. Introduction
 Our design statement
“Design and build the front suspension mount of the Immortus EVX solar car. “
 What is Immortus and what makes it different?
 Grid independent electric vehicle

4. Introduction
 Our design statement
“Design and build the front suspension mount of the Immortus EVX solar car. “
 What is Immortus and what makes it different?
 Grid independent electric vehicle
 Limitations and considerations
 Mass: less mass equals greater overall efficiency
 Space:
 Enclosed wheel well
 Passenger/driver comfort
 Performance: Immortus is a performance car, and must be design as such
 Existing suspension design: We must design a mount for an existing suspension system

5. Introduction
 Our design statement
“Design and build the front suspension mount of the Immortus EVX solar car. “
 What is Immortus and what makes it different?
 Grid independent electric vehicle
 Limitations and considerations
 Mass: less mass equals greater overall efficiency
 Space:
 Enclosed wheel well
 Passenger/driver comfort
 Performance: Immortus is a performance car, and must be design as such
 Existing suspension design: We must design a mount for an existing suspension system
 Specific challenges
 Getting the required strength while keeping weight down
 Acquiring useful materials knowledge.

6. Focus Areas
 Material Selection
 Titanium

7. Focus Areas
 Material Selection
 Titanium
 Carbon Fibre

8. Focus Areas
 Material Selection
 Titanium
 Carbon Fibre
 Aluminium (galvanic corrosion)

9. Focus Areas
 Material Selection
 Titanium
 Carbon Fibre
 Aluminium (galvanic corrosion)
 Manufacturing Techniques
 Carbon Fibre Rod (Stock)

10. Focus Areas
 Material Selection
 Titanium
 Carbon Fibre
 Aluminium (galvanic corrosion)
 Manufacturing Techniques
 Carbon Fibre Rod (Stock)
 Carbon Fibre Moulding (Custom)

11. Focus Areas
 Material Selection
 Titanium
 Carbon Fibre
 Aluminium (galvanic corrosion)
 Manufacturing Techniques
 Carbon Fibre Rod (Stock)
 Carbon Fibre Moulding (Custom)
 3D Titanium Sintering

12. Focus Areas
 Material Selection
 Titanium
 Carbon Fibre
 Aluminium (galvanic corrosion)
 Manufacturing Techniques
 Carbon Fibre Rod (Stock)
 Carbon Fibre Moulding (Custom)
 3D Titanium Sintering
 Mechanical Design
 FBD
 Initial Design
 Titanium buttress
 Carbon fibre buttress
 Carbon fibre truss (space frame)
 FEA

13. Existing Knowledge Base
 Existing information sources
 SAE prior research
 Technical papers and product guides
 3rd Party research papers

14. Existing Knowledge Base
 Existing information sources
 SAE prior research
 Technical papers and product guides
 3rd Party research papers
 Conventional wisdom
 Race car suspension design
 Double Wishbone (Double A Arm)
 Laterally mounted suspension
 Space frames

15. Existing Knowledge Base
 Existing information sources
 SAE prior research
 Technical papers and product guides
 3rd Party research papers
 Conventional wisdom
 Race car suspension design
 Double Wishbone (Double A Arm)
 Laterally mounted suspension
 Space frames
 Conventional materials used in modern performance
vehicles
 Carbon Fibre
 Titanium
 Aluminium
 Steel
880
113.8
414
72.4
600
70
YEI L D. TENS (MP A) S TRENGTH TO W EI GH T YO UNGS MO DUL US (GP A)
PROPERTY COMPARISON
Titanium Alloy (Ti-6Al-4V) Aerospace Aluminum (Al-Cu4-SiMg)
CFRP (120deg Epoxy Cure)

16. Our Design Journey
 Initial mind map

17. Existing Chassis Model

18. Our Design Journey
 Iteration 1: Titanium Buttress
Pros Cons
Relatively simple design Too much material used
Meets strength
requirements
Too heavy
Chassis Mounting Issues

19. Our Design Journey
 Iteration 2: Carbon Fibre Buttress
Pros Cons
Very light Too much material used
Unconventional Shape
will be costly to
manufacture in CF
Too much deflection
Chassis Mounting Issues

20. Our Design Journey
 Iteration 3: Carbon Fibre Truss
Pros Cons
Extremely Light Too much deflection
under compression
Uses off the shelf CF
tube
Occupant interference
Plenty of design
literature
Chassis mounting
issues reduced

21. Our Design Journey
 Iteration 4: Titanium truss with carbon fibre core ( or wrap).
Pros Cons
Extremely Light Little to no
conventional wisdom
Meets initial design
load requirements
Unconventional design
may lead to
unforeseen issues
Minimises titanium
usage
Chassis mounting
issues reduced

22. Current Design
Tubular Titanium Truss with CF Core
 Innovative design synergising existing modern materials and design techniques
 Conventional wisdom did not seem to meet our requirements
 Modern manufacturing techniques require new design paradigm.
 Additive vs subtractive manufacturing
 Must investigate behaviour of composite members
 Literature does exist for individual elements
 Must combine elements in conventional wisdom
 Incremental improvement: Pre or post tensioning members
 Potential new type of high performance design element

23. References
1. Carbon fibre sheet:
https://www.acpsales.com/images/C/DL%20-%20Flex-08.jpg [viewed: 30/03/2016]
2. Carbon fibre tube:
https://www.acpsales.com/images/C/Roll-Wrapped-Tubes.jpg [viewed: 30/03/2016]
3. Titanium mesh ball:
https://i.materialise.com/blog/wp-content/uploads/2012/10/Titanium-ex03.jpg [viewed:
30/03/2016]
Galvanic corrosion bike frame:
http://i1023.photobucket.com/albums/af358/masterquang/Giant%20Cadex%20980c/IMG_4040_z
ps97dac39c.jpg [viewed: 30/03/2016]
Carbon fibre truss node:
http://www.teleskop-express.de/shop/Bilder/shop/ts-ritchey-chretien/rc-truss-tubus-1000.jpg
[viewed: 30/03/2016]
Sintered titanium light sabre handle thing:
http://s3files.core77.com/blog/images/2013/10/4cDesign-QBR-6-Prepolish-Full.jpg [viewed:
30/03/2016]
Double wishbone suspension:
http://www.motor-car.co.uk/images/Suspension/sping/multi-link-suspension.jpg [viewed:
30/03/2016]

24. Questions