Scientific Journal of Silesian University of Technology.

Series Transport
Zeszyty Naukowe Politechniki Śląskiej. Seria Transport

Volume 95 2017

p-ISSN: 0209-3324

e-ISSN: 2450-1549

DOI: https://doi.org/10.20858/sjsutst.2017.95.5

Journal homepage: http://sjsutst.polsl.pl

Article citation information:

Hadula, P., Kaczmarczyk, Ł., Fabiś, P. Powertrain damage analysis for Formula Student car
WT-02. Scientific Journal of Silesian University of Technology. Series Transport. 2017, 95,
47-53. ISSN: 0209-3324. DOI: https://doi.org/10.20858/sjsutst.2017.95.5.

Przemysław HADULA1, Łukasz KACZMARCZYK2, Paweł FABIŚ3

POWERTRAIN DAMAGE ANALYSIS FOR FORMULA STUDENT CAR

WT-02
Summary. This paper is a summary of the design and workmanship of a Formula
Student transmission system vehicle. We conducted simulation research on transmission
system damage. Damage occurred during the Formula Student competition, which is why
we needed to improve the drivetrain system. The article proposes a variant of the change
brackets and carrying out simulation studies on the new construction. For selected models,
the transmission system, which is also determined by its impact on strength and reliability,
is driven by a four-cylinder engine with a displacement of 0.6 dm3.
Keywords: Formula Student; transmission; driveline; MES simulation.

1. INTRODUCTION

Formula Student is an international competition between teams from universities and

technical faculties around the world, which is organized by SAE International. The idea behind
the competition is to design and produce a racing vehicle in accordance with the rules of the
competition. The car created by each must be finished car in a given time and in line with the
need to gain knowledge, strengthen discipline, cooperation and foresight, and often make
compromises. Gained in such circumstances, experience and knowledge are invaluable and

1
Faculty of Transport Silesian University of Technology Krasinskiego 8 street 40-019 Katowice, Poland.
Email: przemysla.hadula@gmail.com
2
Faculty of Transport Silesian University of Technology Krasinskiego 8 street 40-019 Katowice, Poland.
Email: lukaszz.kaczmarczyk@gmail.com
3
Faculty of Transport Silesian University of Technology Krasinskiego 8 street 40-019 Katowice, Poland.
Email:pawel.fabis@polsl.pl
48 P. Hadula, Ł. Kaczmarczyk, P. Fabiś

important aspects of training top-notch engineers. Undoubtedly, this is also a chance to test
their skills in the real world, under the pressure of time and project requirements. What matters
is not only the maximum speed of the car, but the balance between a number of important
elements, namely, speed, economy of operation, aesthetics, functionality and safety. Victory in
the competition only goes to those teams that are able to present a complete project and receive
the highest number of points. With the Formula Student competition, students have the chance
to establish contacts with local industry, while the industry has the opportunity to support the
development of its potential future executives. The basis for the competition is undoubtedly to
support the development of technical thought, while emphasizing how important it is to create
technical universities. As engineering students and professionals play a huge role in human
development, they are of great value to society.

2. CHARACTERISTICS OF THE FORMULA STUDENT COMPETITION

Formula Student is the largest international event organized by the Institution of Mechanical
Engineers and directed mainly at students of technical universities. The patronage of the cycle
of competitions includes the most distinguished engineers associated with the automotive
industry and motorsport (including F1). The aim of the competition is primarily to find talented
students and compare the design of vehicles from all over the world. The competition consists
of two stages: the first is to present a vehicle design and the second is to build the vehicle
according to a detailed specification from SAE International. During the competition, the
judges strictly evaluate each project in terms of its design and engineering approaches.
Furthermore, the vehicle is tested from static and dynamic perspectives, which is why the notion
that this is a typical sport competition recedes into the background.
The static part is devoted to the broader business side and involves preparing a cost production
schedule, developing a business plan and presenting on the special features of the project (i.e.,
design). The second part is directly related to the dynamic competitions involving the designed
and manufactured vehicles. Admission to the dynamic part of the competition is possible after
the painstaking verification of the technical research aspects of each vehicle:
1. Verification as to whether the vehicle complies with the provisions of SAE International’s
procedural rules (scrutineering)
2. Verification of the centre of gravity (tilt)
3. Measurement of engine noise (noise test)
4. Verification of the brakes system (brake test)

The positive completion of all of these tests enables the dynamic events to start, which are
concerned with time measurement and include:
1. Driving on the track in the shape of a figure eight (skid pad)
2. Accelerations of the car at a limited distance (accelerations)
3. Driving on parts of the track (autocross)
4. 20 km main race (endurance)

Points are allocated in the course of these event by professionals, with the totals determining
whether the vehicles will receive specific investments at the end of the competition.
Powertrain damage analysis for Formula Student car WT-02 49.

3. TRANSMISSION SYSTEM CONSTRUCTION FOR THE FORMULA STUDENT

CAR

The object of the research is a racing class Formula Student WT-02 vehicle equipped with a
four-cylinder, four-stroke SI engine, with a capacity of 600 cm3. Originally, this engine was
powered by a carburetted system, which, in the course of adapting the engine to the vehicle,
was converted to a multipoint injection system.

Fig. 1. View of the car and its transmission system

During the project construction, in order to increase the dynamic qualities of the vehicle, a
charging system was applied using a turbocharger. The test transmission and the vehicle are
shown in Fig. 1.
The car was equipped with a torque transfer from the engine to the wheels via a chain
motorcycle. Torque distribution between the wheels is possible through the use of Drexler’s
differential (Fig. 2).

Fig. 2. Visualization of the Formula Student car’s the transmission system

A differential mechanism, including a main gear, was attached to the vehicle frame,
irrespective of the engine and the gearbox. This allowed the separation of the drive system of
the vibration from the engine.
50 P. Hadula, Ł. Kaczmarczyk, P. Fabiś

4. TRANSMISSION SUPPORT MESH SIMULATION RESULTS

When designing the drive system of the vehicle and its attachments, the weight of the vehicle
was reduced in line with the adopted criteria. Every element of the vehicle, including th
powertrain, was subjected to the optimization of weight. The result of these assumptions was
the need to simulate important endurance elements affecting the safety and operation of the
vehicle systems.
During test drives carried out under track conditions, the bracket of the main gearbox and
the differential broke down. The damaged components are shown in Fig. 3.

Fig. 3. Transmission support damage of the Formula Student car

On these photographs, a visible rupture can be seen, along with the broken part of the bracket
located on the main gearbox of the vehicle.

Fig. 4. Transmission system mesh of the Formula Student car

Simulation testing in SolidWorks 2016 was carried out in order to determine how to fix the
problem, as well as improve stability in terms of securing and increasing the vehicle’s strength.
Fig. 4 shows the grid as applied to the powertrain components.
Powertrain damage analysis for Formula Student car WT-02 51.

The differential was modelled and simplified in order to obtain the most real values of
stresses in the material during drive operations. The upper part of the fixing devices was fitted
to the frame’s lower part by the steel brackets. The simple interface between the fasteners
reflected the differential gears, which transmit force to the clamping differential. Applying the
force has a direction and a return consistent with the operation of the drive chain. A force of 10
Kn was applied to the model, which reflected the strength with which the engine torque was
transmitted through the chain to the differential. The original fitting of the differential stress
values significantly exceeded the value of the elastic limit.

Fig. 5. Transmission system simulation of the Formula Student car

Modified support for the differential helped to significantly increase the rigidity and strength
of the structure; at the same time, there was hardly any increase in the mass of the system. Tests
exactly reflected the point of possible damage to the original structure. By applying force to the
new support, the differential had a value of 20 kN, which is twice the value assumptions. During
the test, in addition to the classic mesh, possible damage was caused to the local thickening
grid. The results of simulation testing are shown in Fig. 5.

Fig. 6. Improved transmission system mesh of the Formula Student car

52 P. Hadula, Ł. Kaczmarczyk, P. Fabiś

On the basis of the simulation, the place of greatest deformation was determined, as well as
the loads that corresponded to the site of injury during the test drives. Appropriate modifications
were carried out in order to increasing the vehicle’s rigidity, again by simulating the FEM.
Results of the simulation are shown in Fig. 6 and Fig. 7. The modifications consisted of
changing the profile of the external support and partial filling of the parent material. These
changes effectively improved the rigidity and strength of the bracket.

Fig. 7. Improved transmission system simulation of the Formula Student car

The value of the maximum destructive forces to support the revised powertrain was 20 kN.

5. CONCLUSIONS

In this study, the powertrain simulation allowed for an increase in the reliability of the
vehicle. A strength analysis was carried out using SolidWorks 2016, which precisely defined
the location of the damage. The research led to the following conclusions:
1. Changes in the structure of the bracket resulted in increased stiffness and mechanical
strength
2. Design changes necessitated an increase in the weight of the bracket, while the reliability of
the vehicle increased under track conditions
3. Changing the construction of the transmission support provided an increase in the force by
200%

It seems reasonable to continue research on the optimization reliability of the car and find
some way in which to reduce weight.

References

1. Bąk Roman, Tadeusz Burczyński. 2013. Wytrzymałość Materiałów z Elementami Ujęcia

Komputerowego. Warszawa: Wydawnictwo Nauki i Techniki. [In Polish: Strength of
Materials with Elements of Computer Recognition. Warsaw: Science and Technology
Publishing House]. ISBN: 13 978-83-7926-048-5.
Powertrain damage analysis for Formula Student car WT-02 53.

2. SAE International. 2015. 2015 Formula SAE Rules. Warrendale, PA: SAE International.
3. Durand Keith. 2005. Design of a Chain Driven Limited Slip Differential and Rear Driveline
Package for Formula SAE Applications. Bachelor of Science thesis. Massachusetts Institute
of Technology.
4. Kurowski Paul. 2013. Engineering Analysis with SolidWorks Simulation 2013. Mission,
KS: SDC Publications. ISBN: 978-1-58503-784-1.
5. Rodgers J., P. Willoughby. 1998. Rear Upright and Drive Assembly. Design project.
6. SolidWorks Education. 2016. Fundamentals of 3D Design and Simulation. Waltham, MA:
Dassault Systèmes SolidWorks Corporation.

Received 29.01.2017; accepted in revised form 27.04.2017

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