topology optimization of a prototype race car rear wing pillar
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Elias AMRO
Development Engineer
Tel: +49 89 30 90 89 517
Mob: +49 151 66 41 59 37
elias.amro@adess-ag.com
Topology Optimization of a Prototype
Race Car Rear Wing Pillar
ADESS AG
Balanstrasse 73 Haus 24
D-81541 München
GERMANY
Tel: +49 89 30 90 895 10
Fax: + 49 89 30 90 895 99
info@adess-ag.com
www.adess-ag.com
6th European Altair
Technology Conference
April 22nd-24th 2013
Turin Italy
http://www.lotus-lmp2.com
Advanced Design and Engineering Systems Solutions
Neue Balan campus
Munich, Germany
Formula 1 and Le Mans Prototype
experience
Design Wind tunnel testing
Computational Fluid Dynamics (CFD) Finite Element Analysis (FEA)
Introduction
Tuesday 23rd of April 2013 2013 EATC Turin 2
Introduction
New Le Mans Prototype: Lotus T128 LMP2
Regulations 2014 compliant
2013 World Endurance Championship (WEC)
2 cars sold
LPM1 concept under consideration
Tuesday 23rd of April 2013 2013 EATC Turin 3
Lotus T128 N°32, Free practise session, Silverstone circuit UK, 13.04.2013
Problem definition
Rear wing pillar
Specifications:
Structural aluminium alloy
Yield strength (Sy) = 280MPa
15mm thick plate
1000mmx350mm
8.1kg
Problem: excessive mass of the rear structure of the car
Potential mass savings in rear wing pillar
Aim of the study: minimise the mass of the rear wing pillar while sustaining aerodynamic load and complying with FIA (Fédération Internationale de L’Automobile) regulations
Tuesday 23rd of April 2013 2013 EATC Turin 4
Result of CFD simulation for the car in a straight
line: contour of pressure coefficient and stream
lines
Problem definition
Load cases:
Tuesday 23rd of April 2013 2013 EATC Turin 5
Rear wing pillar initial design with
rear wing assembly
F3/2
F3/2
FIA regulations 2
Vertical static load F1
F2
Maximum speed in straight line
1 Aerodynamic forces
x
z
Analysis
Optimization Constraints:
Optimization process:
→ optimization from closed volume necessarily means reduction in stiffness!
Tuesday 23rd of April 2013 2013 EATC Turin 6
Load case Stress Displacement
1 Sy -
2 Sy 10 mm (z)
Initial CAD concept Non-design space definition
Optimisation cycle OptiStruct
CAD interpretation FEA final check
Results
Final result
Tuesday 23rd of April 2013 2013 EATC Turin 7
Element density plot Initial rear wing pillar
Manufactured rear wing pillar
8.1kg
3.7kg
-54%
mass
1.10mm/kg
0.36mm/kg
+205%
Stiffness to mass ratio
Conclusions
Rear wing pillar reduction in mass
Part behaviour understanding
Rear structure mass target
Tuesday 23rd of April 2013 2013 EATC Turin 8
Elias AMRO
Development Engineer
Tel: +49 89 30 90 89 517
Mob: +49 151 66 41 59 37
elias.amro@adess-ag.com
Thank you
ADESS AG
Balanstrasse 73 Haus 24
D-81541 München
GERMANY
Tel: +49 89 30 90 895 10
Fax: + 49 89 30 90 895 99
info@adess-ag.com
www.adess-ag.com
6th European Altair
Technology Conference
April 22nd-24th 2013
Turin Italy
http://www.lotus-lmp2.com
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