Improved Design of Hub Structure Based on Real Load Spectrum Analysis

The hub is an important part of the suspension structure of racing car. Under the high frequency and high amplitude acceleration, it is prone to fatigue failure due to alternating load, so it is very important to analyze its fatigue life. In this study, based on the real track conditions of the FSAE cars, suspension position sensor and vehicle acceleration sensor are used as the main inputs, combined with vertical load distribution between tires, the load spectrum at the hub is extracted. On this basis, the static analysis and fatigue life prediction of the hub structure are carried out, and the failure forms in the test are reproduced, then the structure of the parts is optimized. The improved design changes the fixed form of the brake disc and optimizes the load transmission path. The finite element analysis shows that the stress at the dangerous point of the new structure is reduced by nearly 50%, and the service life of more than 50000 km can be achieved, which meets the demand of long-time running on the track.