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Design and Analysis of an FSAE Vehicle Chain Sprocket under Static and Fatigue Loading Conditions

Journal Article
05-14-03-0018
ISSN: 1946-3979, e-ISSN: 1946-3987
Published April 13, 2021 by SAE International in United States
Design and Analysis of an FSAE Vehicle Chain Sprocket under Static and Fatigue Loading Conditions
Sector:
Citation: Arora, P., Agrawal, M., Singh, P., Gobinath, N. et al., "Design and Analysis of an FSAE Vehicle Chain Sprocket under Static and Fatigue Loading Conditions," SAE Int. J. Mater. Manf. 14(3):2021, https://doi.org/10.4271/05-14-03-0018.
Language: English

Abstract:

In this study, an attempt is made to deduce the number of teeth in the driven sprocket of a Formula SAE (FSAE) car using Optimum Lap software based on track run simulation of the car, which comes out to be 51 teeth. The sprocket material was selected as Aluminum Alloy AL-7075 T6 because of its strength-to-weight ratio. In addition to it, the generative design strategy by Fusion-360 was utilized to automatically engender the slotted sprocket design on the ground of stress induced on it during operation. Furthermore, the design was verified virtually carrying out static structural and fatigue analysis under the worst-case scenario in CAE software. The overall weight reduction achieved was around 45%. Furthermore, the center-to-center distance between the sprockets and the number of chain links required were also calculated on the basis of space constraints and the wrap angle of the sprocket. The present research work is focussed on the sprocket in order to enhance the transmission efficiency of an FSAE car.