Simulational and Experimental Validation with Structural Redesign of Bearing Housing in a Formula SAE Transmission System

2025-36-0110

To be published on 12/18/2025

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Abstract
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The purpose of the study is to present the validation stages of the transmission bearing housings in a Formula SAE prototype and the redesign of the components to reduce mass. The objective was to design and implement bearing housings that are lightweight while withstanding the loads they are subjected to. A numerical simulation using the Finite Element Method (FEM) was conducted to analyze the behavior of the bearing housings, made of 7075 aluminum alloy, under the same boundary conditions as in the test bench. This simulation provided information on deformation and stresses and was used to determine optimal locations for strain gauge placement. Experimental bench tests were performed, applying forces ranging from 100 N to 600 N. With an application of a 600 N load, an experimental deformation of 1.77E-04 mm/mm was obtained, while FEM indicated 1.71E-04 mm/mm, demonstrating significant correlation, with a 3.4% margin of error. This pattern was observed for all loads, highlighting consistency between methods and validating the model’s accuracy. The same model was used for a simulation considering the vehicle’s boundary conditions on track. The maximum stress obtained was 150 MPa, while the yield stress of the bearing housing material is 495 MPa. Certain regions experienced low stress, indicating potential for geometric modifications and mass reduction, so the bearing housing design was revised, incorporating lightening features in areas of lower stress. The material was changed to 7021 aluminum alloy due to availability. The maximum stress obtained was 230 MPa, whereas the yield stress of the material is around 310 to 340 MPa. A mass reduction of 125 g (30%) was achieved, reducing the total weight from 418 g to 293 g. The bearing design proved to be efficient, as it withstands the loads applied and has a low weight.
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Pages
10
Citation
Kopp, Amanda Fontoura, Roberto Begnis Hausen, and Mario Eduardo Santos Martins, "Simulational and Experimental Validation with Structural Redesign of Bearing Housing in a Formula SAE Transmission System," SAE Technical Paper 2025-36-0110, 2025-, .
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Published
To be published on Dec 18, 2025
Product Code
2025-36-0110
Content Type
Technical Paper
Language
English