Browse Publications Technical Papers 2019-28-0117

Design and Fabrication of CFRP wheel centre for FSAE Race-car 2019-28-0117

The work focuses on the design of a Carbon Fibre Reinforced Polymer (CFRP) Wheel Centre targeting key parameters such as reduced un-sprung mass and lower rotational inertia in the (PRV 2017) Formula-style single seater race car developed for Formula Student Germany. The main issue that was reported by the vehicle dynamics team was to get a customised wheel-offset for our FSAE race-car. To address the issue with an added advantage of reduced un-sprung mass and lower rotational inertia, CFRP wheel centres were introduced. Previously the team used the Keizer Wheel Centre made of Aluminium (1.8 kilograms) which didn’t provide the required wheel-offset as per the geometry designed by the Vehicle Dynamics (VD) team. So, the composite department worked on the development of CFRP 24-layered wheel centre.Designing of CFRP Wheel Centre was based on the design constraints such as distance between hub and wheel assembly to ensure the same geometry of the car as per the design of VD within the set of Formula Student rules. To develop the CFRP Wheel Centre and CAE routine were adopted using Finite Element Analysis. The ANSYS ACP was used to model the 38 layered CFRP wheel centre and the analysis were done to assess optimal the ply orientation and staking sequence. The 38 layers of CFRP was designed to achieve the desired thickness of 12.54 mm to have a proper wheel assembly. The CFRP wheel centre was manufactured and was successful implemented by testing in various conditions with an actual weight of 950 grams.


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