Browse Topic: Motorsports

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Interpretable Tire Force Modeling for Formula Student Vehicle Dynamics and Lap Time Applications2026-01-0762To be published on 07/01/2026
Accurate tire models are a key enabler for vehicle dynamics simulation, control design, and lap time optimization, particularly in the context of Formula Student race cars, where vehicle setups and tire characteristics differ significantly from production vehicles. State-of-the-art tire models, such as Pacejka’s Magic Formula, provide high accuracy but rely on predefined functional structures and a large number of parameters, which limits interpretability and adaptability to new tire compounds. This paper presents a data-driven approach for deriving compact and physically interpretable tire force models using symbolic regression. The proposed method employs an intelligent tree search to systematically explore the space of mathematical expressions and identify models that optimally balance prediction accuracy and structural simplicity. In contrast to black-box machine learning approaches, the resulting models consist of explicit mathematical expressions that enable physical
Anselment, Marcel, Borowski, Julian, Rudolph, Stephan
From Racing Car to Rocket Tank26AERP06_086/1/2026
German startup Blackwave is building carbon parts for rocket tanks. Technical University of Munich, Munich, Germany Carbon fiber has become indispensable in high-performance industries such as automotive engineering and aerospace. It's lightweight, extremely durable, and can be shaped in almost any way. The start-up Blackwave, founded at the Technical University of Munich (TUM), specializes in this versatile composite material. What began with custom components for sports cars and aircraft has evolved into the development of high-pressure tanks for space applications. As is so often the case in engineering, a small detail determines technological progress. In the case of rockets, it is the high-pressure tanks that are specially designed for the fuel systems. As rockets are designed to be as light as possible, they lose structural stability when the fuel tanks, known as primary tanks, are emptied. A trick is used to counteract this: alongside fuel combustion, noble gases are released
A Comparative Assessment of Fuel Cell and Battery Powertrains for Formula Student Electric Applications2026-01-50324/27/2026
The organizers of the most prominent Formula Student competitions have recently initiated a preliminary feasibility study on the application of hydrogen-based propulsion technologies in future single-seater race vehicles. These include electric powertrains with electrochemically converted hydrogen in fuel cell–powered vehicles, competing within the electric championship league. Based on the initial set of regulations, this study presents a model-based comparison between battery-powered (BEVs) and fuel cell–powered electric vehicles (FCVs) for Formula Student. The analysis is conducted using energy, power, and efficiency metrics from four candidate models of propulsion systems, implemented in an open and publicly available MATLAB script: two BEVs with varying battery capacities, and two FCVs employing different hybridization strategies. The aim of this study is to pinpoint and quantify the advantages and disadvantages of each technology for the Formula Student use case, and to identify
Martoccia, Lorenzo, Breda, Sebastiano, Fontanesi, Stefano, d’Adamo, Alessandro
Enhancing the Aerodynamic Performance of Diffusers in High-performance Vehicles Using Trapped Vortex Cavities2026-01-50274/9/2026
Motivated by the inclusion of active flow control provisions in the 2026 Formula One regulations, and building upon previous studies of Trapped Vortex Cavity (TVC) implementation in inverted front wings, this paper investigates the effectiveness of TVC as a flow control mechanism applied to vehicle diffusers. Both active and passive configurations were considered for three diffuser geometries: a base straight-line diffuser, an inverted airfoil-shaped diffuser, and a diffuser inspired by a Formula One car. The study employed numerical simulations to evaluate the aerodynamic performance and the potential benefits of integrating TVC systems. Across all types of diffusers, the implementation of a circular TVC cavity resulted in a significant improvement in the lift-to-drag ratio (CL/CD). In the active flow control configuration, a 10% improvement was observed in the straight diffuser under a limited mass-flow rate. With optimized cavity positioning and radius, the airfoil-shaped and
Ming Kin, NG, Teschner, Tom-Robin
Simulink DevOps Evolution: Bridging Interactive Platforms for Accelerated Model-Based Workflows2026-01-00804/7/2026
This paper builds on last year’s paper presenting DevOps automation in the context of model-based development. Following that paper, we interviewed Simulink users in passenger automotive, motorsports, commercial vehicles, aviation, rocketry, and industrial automation. We discovered that much of the benefit of DevOps platforms to reduce product development cycle time relies on their interactive features. We prototyped new tools to bridge interactive DevOps Git-based platforms with model-based development workflows, and then gathered reactions from another round of interviews. Here we present these interactive DevOps workflows with the feedback from these interviews to contextualize how engineering teams could adopt them to accelerate their own model-based workflows.
Mathews, Jon, Ferrero, Sergio, Tamrawi, Ahmed, Sauceda, Jeremias
Simulation Study on Rear-Wheel Steering Control of FSAE Vehicles Based on Temporal Convolutional Network2026-01-06504/7/2026
The Formula SAE (FSAE) race track is characterized by a large number of corners, making cornering performance a key factor affecting lap time. Based on the proportional control strategy for rear-wheel steering angles, this paper proposes a steering angle optimization method using a Temporal Convolutional Network (TCN). The TCN model features a faster training speed than traditional sequential neural networks. In addition, dilated convolutions enable an exponential expansion of the receptive field without increasing computational costs, making it particularly suitable for capturing the temporal dependencies of vehicle states. By processing vehicle dynamic parameters including front-wheel steering angle, vehicle speed, yaw rate and sideslip angle, the model calculates the correction value of the rear-wheel steering angle. This correction value is then superimposed with the reference value of the rear-wheel steering angle derived from the proportional control strategy, which serves as the
Liu, Xiyuan
Study of the Vortex Flow over a Generic Open-Wheel Race-Car2026-01-06494/7/2026
Open wheel race cars present a challenge to the aerodynamic designer because of the numerous wakes and vortices created by the various body components. The present study follows the development of a high-downforce race car and investigates possible vortex manipulations to increase its aerodynamic efficiency. The tools used for this study involved computational fluid dynamics and small-scale wind tunnel testing. Once the basic geometry of the racecar was finalized, cost effective measures were tested to improve its downforce to drag ratio. As an example, by fine tuning the position of different body components, such as the rear wing location relative to the underfloor diffuser exit, vehicle’s aerodynamic performance can be modified. The results of both the wind tunnel and the computational investigations indicated that such simple modifications can positively improve the race-car downforce to drag ratio. Also, once the baseline vehicle’s geometry was frozen and observing that the
Okpysh, Christian, Katz, Joseph, Shute, Robin
Simulation Study on a Neural Tire Model Based on Grouped Feature Learning2026-01-06454/7/2026
The tire model is a crucial component in the design of the K-characteristic of FSAE racing car suspensions, and directly influences the achievement of maximum cornering lateral force. Not only do the slip angle, vertical load, tire pressure, and camber angle affect the mechanical characteristics of the tire, but temperature is also an important influencing factor when FSAE vehicle tires operate at high speeds. However, the modeling process of traditional tire models based on temperature characteristics is often very complex. The FSAE tire test code (FSAE TTC) already has a large amount of official sample data, which provides a basis for data-driven neural network models. This study implemented a hybrid modeling methodology, constructing two cascaded feedforward neural networks that combine the physical interpretability of the Magic Formula tire model with the nonlinear approximation capabilities of neural networks. The first network model uses slip angle, vertical load, tire pressure
Liu, Xiyuan, Wang, Shenyao, Li, Mingyuan, Huang, Jiayu
Topology Optimization of Multibody Structures Considering Inertial Loads Using an Equivalent Static Displacement Framework2026-01-05014/7/2026
Topology optimization (TO) of dynamic structures has traditionally been constrained to single-body components and simplified harmonic load assumptions. Extending TO to multibody dynamic systems (MBS) remains challenging due to complex coupling between inertia, mass distribution, and joint constraints. This paper presents an inertia-aware topology optimization framework that integrates mass moment of inertia (MMI) constraints within an enhanced Equivalent Static Displacement (ESD) methodology. Building upon the authors’ previously developed ESD framework, the proposed approach — termed Inertia-Augmented Equivalent Static Displacement (IA-ESD) — explicitly incorporates inertial effects arising from accelerations and joint interactions. The approach enables dynamically consistent optimization by coupling design-dependent inertia tensors with equivalent static displacements derived from nonlinear multibody dynamics. Case studies involving an MBB beam and a piston–connecting rod assembly
Gupta, Aakash, Tovar, Andres
A Comprehensive Review of Aerodynamics and Safety of Sports Cars10-10-03-00203/31/2026
As motorsports evolve with technological advancements, aerodynamics plays a crucial role in race car performance. This review examines the impact of aerodynamics on car design and its evolution, presenting a statistical analysis of existing sports cars. We highlight key performance factors like engine power, top speed, drag, and weight. The key contribution of this review is the critical synthesis of the safety-performance trade-off, especially linking aerodynamic optimizations to the stability and safety of sports cars. Furthermore, we explore mathematical modeling of vehicle aerodynamics to enhance the understanding of performance aspects such as top speed, acceleration, cornering, and braking. This article also provides a review of recent active and passive aerodynamic devices to assist researchers in selecting designs, with an emphasis on the importance of ground effect. We also present recent numerical methods, particularly 3D simulations. The statistical data can help researchers
Eftekhari, Hesam, Al-Obaidi, Abdulkareem Sh. Mahdi, Eftekhari, Shahrooz
Experimental Investigations on Appendages of a Racing Motorcycle2026-01-50112/20/2026
In this experimental work, a detailed analysis of the wind tunnel measurements on scaled motorbike models equipped with different front wings was performed considering four wing configurations operating at different Reynolds numbers and roll angles. Global forces acting on the models were measured by a high-resolution dynamometric balance, while velocity fields in the wake were measured by means of the Particle Image Velocimetry technique. Throughout the paper, overall models’ performances are investigated, demonstrating similar behavior for drag coefficients and various trends for lift coefficients. The without- and single-wing configurations were shown to have positive sign, and conversely, the double- and closed-wing cases—with negative sign—generated downforce due to the presence of significant upward velocities, which in turn modified the wake shape. Furthermore, the improvements in closed-wing configuration compared to without- and single-wing ones were noticeable, while slight
Moscato, Giorgio, Romano, Giovanni Paolo
SAE TOMORROW TODAY - The Power of Model-Based Battery Engineering135552/12/2026
Battery development is typically a lengthy and difficult process, but one company is proving that it doesn't have to be. Listen in as we sit down with Gavin White, Co-Founder and Chief Executive Officer, About:Energy, to discover how model-based design and advanced simulation are revolutionizing battery development -- cutting timelines by up to 70%. You'll also learn about the creation of The Voltt database, a game-changing resource for engineers and manufacturers. From motorsports to satellites to microgrids in developing regions, this conversation is proof that batteries are shaping the future of energy, technology, and society. We'd love to hear from you. Share your comments, questions and ideas for future topics and guests to podcast@sae.org. Don't forget to take a moment to follow SAE Tomorrow Today--a podcast where we discuss emerging technology and trends in mobility with the leaders, innovators and strategists making it all happen--and give us a review on your preferred
Patterson, Lori
SAE TOMORROW TODAY - SAE: Where Meaningful Relationships Take Shape135531/30/2026
Curious how SAE can open doors in the automotive industry and beyond? Listen in as we sit down with Dean Case, Membership Director, SAE SoCal, whose 45-year journey in the automotive industry is packed with stories of racing, engineering, and community building. From joining SAE as a Cal Poly student to shaping the future of motorsports and electric vehicles at Mazda, Ford, and Nissan, learn how SAE International became a springboard to building lifelong connections and uncovering new opportunities. Whether you're a student, engineering professional, or automotive enthusiast, this conversation is packed with inspiration, practical advice, and proof that SAE provides a firm foundation for meaningful relationships that last. We'd love to hear from you. Share your comments, questions and ideas for future topics and guests to podcast@sae.org. Don't forget to take a moment to follow SAE Tomorrow Today--a podcast where we discuss emerging technology and trends in mobility with the leaders
Patterson, Lori
Modelling and Simulation of Key Vehicle Dynamics Parameters for a Conceptual Race Car2026-26-00851/16/2026
Vehicle dynamics is a vital area of automotive engineering that focuses on analyzing how a vehicle responds to driver inputs and external factors like road conditions and environmental influences. Achieving optimal performance, safety, and ride comfort requires a detailed understanding of longitudinal, lateral, and vertical dynamic behavior. The objective of this paper is to develop and validate the model of a concept Race car and evaluate its vehicle dynamics behavior using IPG CarMaker, a high-fidelity virtual testing environment widely used in industry. The model incorporates a range of vehicle parameters, including suspension parameters like spring and damper characteristics, mass distribution, tire properties and powertrain parameters. The performance evaluation is done as per standard guidelines, including Constant Radius turn test, Sine Steer test and other standard tests like Acceleration, Braking along with Ride and Comfort classification. The key parameters that are
Agrewale, Mohammad Rafiq B., Vaish, Ujjwal
Development of a Data Acquisition System for an Electric Formula SAE Vehicle2025-36-015112/18/2025
The acquisition of sensor data is essential for the operation and validation of the SAE vehicle. This system must be capable of converting analog data into digital form and communicating with the sensors. To this end, printed circuit boards (PCBs) were designed and manufactured, incorporating electromagnetic interference mitigation solutions through various analog filters, in order to ensure the integrity of the acquired signals. Data conversion and communication were implemented using a microprocessor from the STM32 family, with efficient transmission of the processed data carried out via the CAN protocol.
David, Mateus Padilha, Andrade, Fernanda Matsumoto Lima, Sousa Oliveira, Ivan, Carvalho, Luis Pedro Feio, Guerreiro, Joel Filipe, Ribeiro, Rodrigo Eustaquio, Santos Neto, Pedro José
A Simulation and Design Approach of Battery Pack for Formula SAE Vehicles2025-36-014112/18/2025
The objective of this article is to present an approach for simulating and analyzing the battery pack in the Matlab/Simulink environment. The proposed approach investigates the expected performance of the vehicle with a given battery pack and powertrain configuration. For this purpose, an equivalent circuit model of a commercially available cell was used in the simulation. Additionally, track data from previous projects was employed, consisting of speed logs from Formula SAE competition test tracks, including the battery pack’s behavior in those same competitions. Based on these results, data processing was performed to estimate the expected behavior of a battery pack, considering weight, size, power, capacity, and other constraints. Since the goal is to observe the battery pack’s performance in the various Formula SAE events, past competition data was used to estimate the current car’s behavior. Therefore, the main contribution of this work is the presentation of a proper simulation
Zackiewicz, Felipe Petrillo Fici, Trentin, Fernando Santos, Dias, Gabriel Henrique Rodrigues, Eustaquio, Rodrigo, Ribeiro, Santos Neto, Pedro José dos, Guerreiro, Joel Filipe
A Structured Approach to Tire Selection in Formula SAE: Balancing Performance and Requirements2025-36-017112/18/2025
Tires are fundamental components of Formula SAE race cars, serving as the only point of contact between the vehicle and the track. Their performance directly influences critical aspects such as handling, stability, cornering behavior and lap times, making tire selection a vital factor in vehicle dynamics. However, choosing the optimal tire is a complex challenge due to the wide range of available options and the need to balance multiple performance parameters. While many studies analyze tire behavior, few focus specifically on the demands of Formula SAE vehicles. Those that do often rely on overly complex methodologies or subjective assumptions, resulting in a lack of practical and systematic approaches to decision-making. This study addresses this gap by developing a structured approach for tire selection, designed to meet the specific needs of Formula SAE teams. The proposed approach analyzes a typical Formula SAE endurance track, acceleration, skid pad, and autocross circuit to
Rocha Checheliski, Carolina Dias da, Martins, Mario Eduardo Santos, Hausen, Roberto Begnis
The Racing & High-Performance TireR-59412/17/2025
The Racing & High-Performance Tire originally published in 2003 and continues to be a best-seller. Following up on his first two books, Inside Racing Technology and Inside Racing: A Season with the PacWest CART Team, Paul Haney presents a new book revealing the complexities of tires, how they influence vehicle dynamics, and how to use tires in the engineering of racing and high-performance cars. More than 150 photos and drawings help the reader learn the colorful history and unique characteristics that make the pneumatic tire one of the world's most complex and useful products.
Haney, Paul
Dynamics Simulation Analysis of a Formula Racing Car with a Novel Rear Wing Based on Carsim2025-99-040312/10/2025
Because regular rear wings on race cars cannot meet all aerodynamic needs, this study tests a new active rear wing on a formula racing car. First, the paper explains the design and key features of the new wing, showing how it helps improve airflow and downforce. Then, the study builds a model of the racing car in Carsim software and adds the new wing to test its performance. After that, simulations compare the new wing to traditional ones, focusing on speed, grip, and handling. The results prove that the new wing makes the car faster and more stable in corners. This means the active rear wing is a better solution than fixed wings, and it could be useful for future race car designs.
Yu, Wanbo
Characterization of the Brake Linings Coefficient of Friction by Means of Instrumented Suspensions Equipped on a Hybrid Race Vehicle10-10-01-000411/8/2025
The knowledge of the brake linings coefficient of friction (BLCF) is crucial for the control of the braking moment in modern vehicles equipped with electric powertrains. In the case of race vehicles equipped with carbon–carbon brakes, the coefficient of friction exhibits great variations as a function of the main influencing factors, namely the pressure, the temperature, and the sliding speed at the pad–disc interface. In this work, a Le Mans Hypercar instrumented with more than 150 sensors was adopted to perform the characterization of the BLCF from racetrack acquisitions. The front and rear left suspensions of the vehicle were instrumented with strain gauge channels and position transducers to acquire the reaction loads at the upright and the orientation of the arms. Then, the geometric matrix method was implemented for calculating the moments at the upright from which the braking torque was derived without the need to know any of the wheel inertia, nor the driveshaft torque. Data
Cortivo, Davide, Vendramin, Mattia, Dindo, Luigi
Simulation-Based System-Level Design Optimization for Formula SAE Vehicles2025-01-038010/7/2025
System-level design decisions in Formula SAE (FSAE) vehicles drive all downstream subsystem designs, yet these decisions are often based on historical precedent or anecdotal evidence rather than rigorous analysis. This work presents a simulation-driven methodology to support data-informed decisions early in the design process, specifically examining how overall vehicle parameters—such as engine power, vehicle mass, aerodynamic drag and lift, wheelbase, and track width—influence performance in a representative FSAE endurance scenario. Two types of lap-time simulation tools were used in this study: OpenLAP, a point-mass simulator, and ChassisSim, a transient 3D vehicle dynamics simulator that incorporates suspension geometry, yaw response, weight transfer, and steering effects. Initial simulations with OpenLAP were used to rapidly identify trends and guide early design decisions, while ChassisSim was used for detailed sensitivity analyses and to validate system-level trade-offs in a more
Hernandez, Andy Jose, Bachman, John Christopher
Enhancing Robustness of Electro-Hydraulic Brake-by-Wire Actuators via Linear Active Disturbance Rejection Control2025-01-03419/15/2025
In recent years, motorsport has increasingly focused on environmental concerns, leading to the rise of hybrid and fully electric competitions. In this scenario, electric motors and batteries take a crucial role in reducing the environmental impact by recovering energy during braking. However, due to inherent limitations, motors and battery cannot fully capture all braking power, necessitating the use of standard friction brakes. To achieve an efficient balance between electric motors and friction brakes, the brake pressure can no longer be directly controlled by the driver. Instead, it must be computed by the Vehicle Control Unit (VCU) and sent to a smart actuator, i.e. the Brake-By-Wire (BBW), which ensures that the required pressure is applied. The standard approach to achieve precise pressure control is to design a nested Proportional-Integral-Derivative (PID) control architecture, which requires an accurate nominal model of the system dynamics to meet the desired tracking
Gimondi, Alex, Dubbini, Alberto, Riva, Giorgio, Cantoni, Carlo
Thermal Characterisation of a High-Power Lithium-Ion Pouch Cell and Surface Temperature Prediction for Motorsport Applications2025-24-01429/7/2025
Accurate cell thermal characterisation is vital for battery modelling and thermal management, especially in motorsport, where minor temperature estimation errors can have severe consequences. Conventional methods for determining key thermal parameters, such as the specific heat capacity, often require costly calorimeters or destructive testing. Recent studies propose an alternative approach using a 1D lumped thermal network to solve the thermal balance of a heat-generating cell. However, these studies often overlook critical aspects of the heat generation equation, particularly the entropic term, which is essential for capturing nonlinear thermal behaviour, especially under dynamic cycling conditions. This study presents a cost-effective approach for rapid cell thermal characterisation and accurate surface temperature prediction. A pouch LCO cell was first tested to determine the entropic coefficient, followed by experiments under two convective conditions to evaluate its specific heat
Sciortino, Davide Domenico, Schommer, Adriano, Costa, Andre
How Battery Simulation Is Taking High-Performance EV Development to New HeightsTBMG-535288/1/2025
In today’s electric age, the definition of ‘high-performance’ is being rewritten, courtesy of electric sports cars, supercars, and hypercars pushing limits that were once thought impossible to reach. Even Formula 1, quite surprisingly to many, has embraced electrification by integrating hybrid electric systems at the pinnacle of motorsport. Every jaw-dropping 0 to 60 mph time or record-breaking lap is backed by a battery system engineered with precision. Increasingly that precision is driven by simulation technology.
Q&A25AUTP08_138/1/2025
Lyten is best-known as the developer of next-gen lithium-sulfur (Li-S) battery technology. SAE Media spoke with Keith Norman, Lyten's chief sustainability officer, on how 3D Graphene is getting Lyten to branch out into motorsports.
Blanco, Sebastian
Automation and Optimization of the Design and Development Process for a Formula Student Racing Car Suspension2025-01-02707/2/2025
The design, development, and optimization of modern suspension systems is a complex process that encompasses several different engineering domains and disciplines such as vehicle dynamics simulation, tire data analysis, 1D lap-time simulation, 3D CAD design and structural analysis including full 3D collision detection. Typically, overall vehicle design and suspension development are carried out in multiple iterative design loops by several human specialists from diverse engineering departments. Fully automating this iterative design process can minimize manual effort, eliminate routine tasks and human errors, and significantly reduce design time. This desired level of automation can be achieved through digital modeling, automated model generation, and simulation using graph-based design languages and an associated language compiler for translation and execution. Graph-based design languages ensure the digital consistency of data, the digital continuity of processes, and the digital
Borowski, Julian, Rudolph, Stephan
Early Detection of the Loss of Control of Motorsport Vehicles10-09-03-00296/30/2025
The article investigates how to detect as quickly as possible whether the driver will lose control of a vehicle, after a disturbance has occurred. Typical disturbances refer to wind gusts, obstacle avoidance, a sudden steer, traversing a pothole, a kick by another vehicle, and so on. The driver may be either human or non-human. Focus will be devoted to human drivers, but the extension to automated or autonomous cars is straightforward. Since the dynamic behavior of vehicle and driver is described by a saddle-type limit cycle, a proper theory is developed to use the limit cycle as a reference trajectory to forecast the loss of control. The Floquet theory has been used to compute a scalar index to forecast stable or unstable motion. The scalar index, named degree of stability (DoS), is computed very early, in the best case, in a few milliseconds after the disturbance has ended. Investigations have been performed at a dynamic driving simulator. A 14 DoF vehicle model, virtually driven by
Della Rossa, Fabio, Fontana, Matteo, Giacintucci, Samuele, Gobbi, Massimiliano, Mastinu, Giampiero, Previati, Giorgio
Design of a Reactive-Style Muffler for a Formula SAE Race Car2025-01-00245/5/2025
The noise generated by high-performance vehicles like Formula SAE (FSAE) race cars, presents a significant challenge in adhering to strict competition noise regulations. In this study two muffler designs were created: muffler design 1 and 2. Each design utilized two chambers to generate destructive interference, targeting two dominant exhaust frequencies of the Honda CBR600RR engine to maximize transmission loss and reduce sound pressure levels (SPL) below the FSAE-mandated range of 103 dBC at idle and 110 dBC at all other operating conditions. For each design, the exhaust noise and muffler performance were simulated using GT-Suite, allowing for an evaluation of noise attenuation across engine speeds. Experimental testing was conducted to validate the GT-Suite model and assess the effectiveness of muffler design 1. This testing involved measuring the SPL with a calibrated microphone, both with and without the designed muffler. Muffler design 1 was based on the dominant exhaust
Labao, Kai, Middleton, Nicholas, Nuszkowski, John
Optimization of Gusset Geometry for Racecar Frame Design2025-01-50335/1/2025
This research optimizes sheet metal gusset geometry to support a suspension pickup point in a Formula SAE racecar. The sheet metal gusset design incorporates an external radial cut-out and an internal triangular cut-out, each of which can be adjusted in size to optimize the stiffness to mass ratio. A finite element analysis was set up using a heavy braking load case, which applied 3900 N to the suspension point being supported by the gusset. A parametric optimization (finite element analysis) was run in SolidWorks to gather mass and stiffness data for each of the 143 designs under the prescribed load case. The parametric optimization was run on both a simulated front hoop and a test fixture, which showed a similar trend in their results. Experimental testing was performed on three designs. The gusset profiles were waterjet and TIG welded to the test fixture tube frames. The results of the test agreed with the simulation results with a discrepancy of less than 10% in all cases. The
Burggraf, Jacob, Willerth, Stephanie Michelle, Yu, Bosco
On the Application of Trapped Vortices in Motorsport Application for Improved Aerodynamic Performance Using Passive and Active Flow Controls2025-01-50294/15/2025
New regulations introduced by the Fédération Internationale de l’Automobile (FIA) for the 2026 Formula 1 season mark the first instance of active flow control methods being endorsed in Formula 1 competition. While active methods have demonstrated significant success in airfoil development, their broader application to grounded vehicle aerodynamics remains unexplored. This research investigates the effectiveness of trapped vortex cavity (TVC) technology in both active and passive flow controls, applied to a NACA0012 airfoil and an inverted three-element airfoil from a Formula 1 model. The investigation is conducted using numerical methods to evaluate the aerodynamic performance and potential of TVC in this paper. In the single-airfoil case, a circular cavity is placed along the trailing edge (TE) on the suction surface; for the three-element airfoils, the cavity is positioned on each airfoil to determine the optimum location. The results show that the presence of a cavity, particularly
Ng, Ming Kin, Teschner, Tom-Robin
T.R.I.C.K. 2.0: Enhanced Vehicle Dynamics Analysis and Estimation Harnessing Advanced Vehicle Sensors10-09-03-00254/9/2025
Automotive signal processing is dealt with in several contributions that propose various techniques to make the most out of the available data, typically for enhancing safety, comfort, or performance. Specifically, the accurate estimation of tire–road interaction forces is of high interest in the automotive world. A few years ago the T.R.I.C.K. tool was developed, featuring a vehicle model processing experimental data, collected through various vehicle sensors, to compute several relevant virtual telemetry channels, including interaction forces and slip indices. Following years of further development in collaboration with motorsport companies, this article presents T.R.I.C.K. 2.0, a thoroughly renewed version of the tool. Besides a number of important improvements of the original tool, including, e.g., the effect of the limited slip differential, T.R.I.C.K. 2.0 features the ability to exploit advanced sensors typically used in motorsport, including laser sensors, potentiometers, and
Napolitano Dell’Annunziata, Guido, Farroni, Flavio, Timpone, Francesco, Lenzo, Basilio
Optimization Design of Formula E Racing Car Transmission and Wheel System2025-01-85054/1/2025
The paper provides a detailed analysis of the transmission system design under the single motor drive scheme, with a focus on the 2024 Formula SAE (FSAE). The selection of the motor type is determined based on race rules and battery box output power limits. In terms of transmission ratio design, this study takes into account the car's power, balancing acceleration ability and maximum speed to determine an optimal transmission ratio through theoretical calculations and empirical values. Furthermore, it explores how to optimize overall drive system performance by considering technical parameters, power requirements, economic considerations of each system assembly, and validates these findings through software simulations. Notably, significant improvements in reliability are achieved with the newly designed transmission system and wheel rim system while also proposing lightweighting methods for key components. We have carried out extensive verification in both simulation and real vehicle
Wang, Liuxin, Li, Chengfeng, Zhu, Xiran, Liu, Minmin
Establishment of Failure Simulation Models for Bonding of Carbon Fiber Laminated Skins and Cores in Monocoque Structures Based on Formula Student Racing Cars2025-01-80064/1/2025
In Formula SAE , the primary function of the frame is to provide structural support for the different components and withstand the applied load. In recent years, most Formula Student teams worldwide to adopt monocoque made of carbon fiber composites, which are lighter and stronger. Enhancing the mechanical performance of carbon fiber laminates has been a key focus of research for these teams. In three-point bending tests, significant stress at the adhesive layer between the skin and the core material at both ends of the laminate, often lead to potential adhesive failure. Consequently, experimental boards often exhibit delamination between the outer skin and the core material, and premature core crushing, which compromises the mechanical performance of the laminate and fails to pass the Structural Equivalency Spreadsheet. Therefore, it is necessary to consider the influence of the bonding factor of toughened epoxy prepreg film on the mechanical properties of the laminated plate. This
Ning, Zicheng
A Design of Electric Drive System for All-Wheel Drive Formula Student Racing Car to Improve Racing Performance2025-01-80054/1/2025
This paper introduces an innovative in-wheel electric drive system designed for all-wheel drive Formula Student Electric racing cars. The system utilized AMK's DD5-14-10-POW-18600-B5 model as the driving motor, with a gearbox transmission ratio of 13.2 determined through Optimum Lap simulation. A two-stage gear reducer was integrated into a unified hub-spoke assembly, which connected directly to the ten-inch carbon fiber rim. In this paper, three conventional FSEC planetary gear reducer shafting designs are introduced, and a new shafting structure is proposed. Then the four structures are compared in multiple dimensions. Subsequently, we designed the shafting of the gear group, determined the size parameters of the shafting structure and the bearing type, and completed the verification. The planetary carriers were integrated with the wheel-edge suspension columns. Meanwhile, a special floating brake disc mounting method was employed, which increased the brake disc's heat capacity by
Guo, Ruijie, Zeng, Junhao, Yang, Yuancai, Hou, Yijie, Zhu, Zhonghui, Xiong, Jiaming
Cost-Effective Sideslip Measurement: Beta for the People!2025-01-87964/1/2025
Vehicle sideslip is a valuable measurement for ground vehicles in both passenger vehicle and racing contexts. At relevant speeds, the total vehicle sideslip, beta, can help drivers and engineers know how close to the limits of yaw stability a vehicle is during the driving maneuver. For production vehicles or racing contexts, this measurement can trigger Electronic Stability Control (ESC). For racing contexts, the method can be used for driver training to compare driver techniques and vehicle cornering performance. In a fleet context with Connected and Autonomous Vehicles (CAVS) any vehicle telemetry reporting large vehicle sideslip can indicate an emergency scenario. Traditionally, sideslip estimation methods involve expensive and complex sensors, often including precise inertial measurement units (IMUs) and dead reckoning, plus complicated sensor fusion techniques. Standard GPS measurements can provide Course Over Ground (COG) with quite high accuracy and, surprisingly, the most
Hannah, Andrew, Compere, Marc
Development and Validation of a Rear Head Surround Foam Performance Specification for Stock Car Racing2025-01-83534/1/2025
Over the last two decades many improvements have been made in stock car racing driver safety. One of these is the head surround, which is rigidly secured to and an integral part of the NASCAR (National Association for Stock Car Auto Racing, LLC) seating environment and serves as an effective restraint for head protection during lateral and rear impacts. However, previous head impact material specifications were optimized for moderate to severe impacts and did not address low severity impacts that occur frequently during typical driving, such as race restart vehicle nose-to-tail contact. This study focused on developing a test methodology for comprehensive evaluation of rear head surround materials for low, moderate and severe impacts. Specifically, this study aimed to formulate a specification that maintains previous material performance during high speed impacts, while decreasing head accelerations at low speed impacts. Quasi-static and dynamic drop tower testing of sample materials
Gray, Alexandra N., Harper, Matthew G., Mukherjee, Sayak, Patalak, John P., Gaewsky, James
Optimal Investigation About Cab of BSC Racing Car Based on Ergonomics2025-01-86694/1/2025
In the Baja race, off-road vehicles need to run under a variety of real and complex off-road conditions such as pebble road, shell pit, stone bad road, hump, water puddle, etc. In the process of this high-intensity and high-concentration race, the unoptimized design of the cab in ergonomics will easily cause the driver's visual and handling fatigue, so that the driver's attention is not concentrated. Cause the occurrence of security accidents. Moreover, lower back pain, sciatic nerve discomfort, lumbar spine diseases and other occupational diseases are basically caused by uncomfortable driving posture and unreasonable control matching, and these have a lot to do with unreasonable ergonomic design. In order to solve these problems, firstly establish the human body model of the driver, and then build the BSC racing car model by using 3D modeling software Catia. Then use the ergonomics simulation software Jack to analyze the visibility, accessibility and comfort. Based on the simulation
Liu, Yuzhou, Liu, Silang
Design and Evaluation of an Adjustable Ackermann Rate Steering System for Formula Student Racing Cars2025-01-80004/1/2025
FSAE is a competition designed to maximize car performance, in which the steering system is a key subsystem, and the steering system performance directly affects the cornering performance of the car. The driver relies on the steering system for effective handling, which is also crucial for cornering and achieving faster lap times. Therefore, while improving the performance of the steering system, it is crucial to match the vehicle design to the driver's habits. Traditionally, steering systems typically use an Ackermann rate between 0% and 100% to offset the slip angle caused by tire deformation, thus achieving the purpose of reducing tire wear. Calculations have shown that a 40-60% Ackermann rate provides a similar compensation effect with little difference in tire wear. The traditional steering design method also does not consider the driver's driving habits and feedback, which is not conducive to the improvement of the overall performance of the car. In FSAE's figure-of-eight loops
Wu, Hailin, Li, Mingyuan
Research and Structural Optimization of Lattice Core based on Monocoque of Formula Student Racing Car2025-01-80034/1/2025
Monocoque is a kind of integrated shell structure technology, which has gradually become the primary choice for various racing teams to make car bodies because of its advantages of small specific gravity and high specific strength. The unit of the monocoque is a carbon fiber composite sandwich structure, which is composed of two layers of carbon fiber skin inside and outside and core material between them. The inner and outer layers of the carbon fiber skin are stacked with carbon fiber composite materials of different directions and types.In this project, we plan to optimize the shape of the monocoque shell using the surface design software Alias, select core materials of different materials and structures, more advanced layups, and obtain feasible layup sequences and core material types through Ansys simulation and Matlab collaborative optimization, which will be verified by three-point bending experiments. Different from the previous lightweight work based a lot on experience, this
Cheng, Zhu H., Liu, JJ
Development and Performance Optimization of Formula SAE Racing Active Ground Effect System Based on Fan Drive2025-01-80014/1/2025
For Formula SAE cars, a significant increase in downforce can enable the car to score more points in the race and enhance the competitiveness of the vehicle. This paper focuses on the development of an active ground effect system driven by fans for the FSAE racing car. The system is designed to considerably increase the downforce of the racing car through the forced airflow generated by the fan, enable the dynamic adjustment of the aerodynamic balance of the racing car during the driving process, and achieve the vertical force control on the racing wheels, thereby improving the performance of the racing car. The Star-CCM+ software was employed to conduct CFD simulation to investigate the influence of different flow fans on downforce and optimize the layout and position of the fan. Due to the limited power that the car can carry, the paper will also simulate and calculate the range of pneumatic balance adjustment and vertical force control capability provided by the different openings
Yang, Chengyue
Numerical Investigation on Motorsport Overtake Manoeuvre in Crosswind Conditions2025-01-87734/1/2025
Existing technical literature has primarily focused on the upstream wake effects of single-seater race cars during overtaking, often neglecting the critical factor: crosswinds. This study presents a quantitative computational fluid dynamics (CFD) analysis of how crosswinds impact the aerodynamic loads of interacting race car models during an overtake manoeuvre. For numerical validation purposes, a wind tunnel experimental campaign was carried out on a 35%-scale hill climb race car model to evaluate aerodynamic forces and wake pressure mappings at different ride heights. RANS-based simulations were performed to assess the impact of crosswinds (β = 2°, 6°, 10°) on an isolated race car. Subsequently, a quasi-static approach was used to quantify the effect of crosswind (β = 10°) on an overtaking car under different path strategies. The findings indicated that the overtaking car's performance remained largely stable when a driver opts for overtake paths against the crosswind direction (i.e
Makhija, Jai, Soares, Renan F.
Study on Ergonomic Design Optimization and NVH Characteristics of Baja Racing Car2025-01-86124/1/2025
As a kind of off-road racing car, the driving condition of Baja is extremely bad. In order to allow the driver to control the vehicle well in complex working conditions, it is particularly important to provide a comfortable and convenient driving space and handling space for the driver. In this paper, firstly, RAMSIS is used to carry out the ergonomics verification of the racing car from the comfort analysis, reachable area analysis and visual field analysis, and optimize the design of the cockpit layout of the Baja racing car. Then the NVH characteristics of the Baja racing car frame are studied, and the 12-order modal results are obtained by finite element analysis and simulation. Then the natural frequency of the frame is measured by experiments, and the experimental results are verified to match the theoretical values. The research shows that the above steps can design a comfortable driving posture and operating space for the racer and provide experience for the future layout of
Liu, Silang
Optimized Design and Analysis of a High-Performance, Track-Focused Quad Bike for the Indian Market2025-28-00612/7/2025
This paper presents a complete approach to the optimized design and analysis of a trach-focused quad bike suitable for the Indian market. The process of design integrates several analytical factors, including driver ergonomics, aesthetics, and strategic component placement, to establish optimum vehicle dimensions. The primary objective is to address the unique demands of the Indian terrain and user preferences through ensure comfort, functionality, and visual appeal. The selection process for tires and suspension geometry is precisely conducted with the advanced OptimumKinematics software. This optimization provides greater performance and stability that the vehicle can accurately manage a variety of road conditions. The space frame chassis of a vehicle’s core structure features, engineered to minimalize tubing and facilitate ease of fabrication, contributing to both structural integrity and weight reduction. A robust 600cc four-cylinder engine is selected that emphasizing an optimal
Thanikonda, Praveen Kumar, Shaik, Amjad, Tappa, Raju, Ratlavath, Ramu, Navar, Adarsh, Challa, Ajith Kumar
Numerical Study of Aerodynamic Flow and the Effects of Spoiler Wings on a Formula Student Race Car2024-01-52471/28/2025
Current work details the preliminary CFD analysis performed on custom-built race car by Team Sakthi Racing team as part of Formula SAE competition using OpenFOAM. The body of the race car is designed in compliance with FSAE regulations, OpenFOAM utilities and solvers are used to generate volumetric mesh and perform CFD analysis. Formula student tracks are typically designed with numerous sharp turns and a few long straights to maintain low speeds for safety. In order to enhance the cars’ performance in sharp turns, the race car should be equipped with aerodynamic devices like nose cone and wings on both the rear and front ends within the confines of the formula student racing rules. Thus, efficient aerodynamic design is highly critical to maximizing tire grip by ensuring consistent contact with the track, reducing the risk of skidding, and maintaining control, especially during high-speed maneuvers. In this work, the performance and behavior of the race car, both with and without the
Rangarajan, Kishore, Pushpananthan, Blesscin, Anumolu, Lakshman, Selvakumar, Kumaresh, Jayakumar, Shyam Sundar
Enhancing Engine Lubrication: Design and Evaluation of Oil Sump Surge Control in Racing Vehicles2024-36-007412/20/2024
During accelerations and decelerations of a race car whose engine has a wet sump, the forces generated by the vehicle’s motion cause the engine oil to vigorously shift towards the walls of the oil pan and crankcase, contributing to the phenomenon known as ‘sloshing.’ This phenomenon often leads to fluctuations in oil pressure, resulting in oil pressure surge, when the oil is pushed away from the pump pickup point. Via the logged data, the Formula UFSM FSAE Team had witnessed a recurrent lack of oil pressure in the race track during the 2023 Brazilian FSAE competition. In the AutoCross Event, the recurrence of this problem was 80% of the right corners on lateral accelerations between 0.80G and 1.30G. The average oil pressure in this condition was 0.80 bar, even reaching 0.10 bar above 5000 RPM. Therefore, it was necessary to develop a new set of baffles for the oil pan, capable of minimizing the effects of sloshing and, consequently, the oil surge. As a method of research, a test bench
Zimmermann, Natalia Diovana, Junior, Luiz Alfredo Coelho, Martins, Mario, Hausen, Roberto
Optimization of a 2-D Multi-Element Rear Wing on a Formula 1 Car2024-36-010312/20/2024
The aerodynamic force produced by external flows over two-dimensional bodies is typically decomposed into two components: lift and drag. In race cars, the lift is known as downforce and it is responsible for increasing tire grip, thereby enhancing traction and cornering ability. Drag acts in the direction opposite to the car’s motion, reducing its acceleration and top speed. The primary challenge for aerodynamicists is to design a vehicle capable of producing high downforce with low drag. This study aims to optimize the shape of a multi-element rear wing profile of a Formula 1 car, achieving an optimal configuration under specific prescribed conditions. The scope of this work was limited to a 2-D model of a rear wing composed of two 4-digit NACA airfoils. Ten control parameters were used in the optimization process: three to describe each isolated profile, two to describe their relative position, and two to describe the angles of attack of each profile. An optimization cycle by finite
Souza Dourado, Guilherme, Hayashi, Marcelo Tanaka
Modeling and Simulation of an Electromagnetic Brake-by-Wire System for Formula SAE Vehicles2024-36-016912/20/2024
Electric vehicles represent a shift towards sustainability in the automotive industry, with the Brake-by-Wire (BBW) system as an innovation to enhance safety, and performance. This study proposes an electromagnetic BBW system for Formula SAE vehicles, optimizing an electromagnet with a genetic algorithm as the actuator. Through a selection process from a million individuals, the system was modeled. Integrated with electric motors using CarMaker® software, the optimized electromagnet surpassed the minimum required force of 228.08 N without reaching its nominal current of 12.5 A, achieving a force of 231.1 N for 150 W power, indicating an energy efficiency of 0.706 N/Watt. The system also exhibited a response time of 17.92ms for an 80 bar increase, 1.52 times better than compared systems. Simulation under varying braking intensities demonstrated dynamic behavior, with settling times for slow, moderate, and sharp braking at 193 ms, 62 ms, and 21 ms, respectively. Efficiency during
Salgado, Vinícius Batista Alves, Gomes, Deilton Gonçalves, Andrade Lima, Cláudio
Verification of Continuously Variable Transmission Performance Tuning Based on Bacha Racing Vehicle’s Power Matching and Transmission Performance2024-01-509710/15/2024
Due to the compact structure of the Bacha Racing vehicle, the continuously variable transmission (CVT) serves as a crucial transmission component. It is essential to tune and verify its performance to ensure the power matching and transmission efficiency of the entire vehicle. This paper conducts a kinematic analysis of CVT based on transmission theory, designs real vehicle traction experiments, and CVT bench tests. Additionally, it proposes a method to utilize Hall sensors for real-time monitoring of CVT motion to assist in its tuning. The results demonstrate that the optimal performance tuning of the CVT for the Bacha Racing vehicle has been achieved through various experiments.
Li, He
Automotive Engineering: September 202424AUTP099/5/2024
BMW, Classiq find better architectures through quantum computing Everything from electric motors to robot arms can be looked at through the lens of a powerful algorithm. Blazer EV is a steel-intensive showcase GM elevates the ferrous state-of-art with new body and battery structures. Steel targets EV structures, battery boxes The industry fires back at aluminum's growing 'gigacasting' threat. Editorial No, really, what's an SDV? Supplier Eye A new reckoning Altair honors innovations in automotive lightweighting and sustainability GM EVs will soon provide V2H backup power during blackouts Supplier technologies could deep-freeze the steering wheel Mazda Motorsports keeps the MX-5 cool with a new differential plate 2025 Lucid Air review: unnecessarily fast, astonishingly efficient Refreshed 2025 Cadillac Escalade features 55-inch dash display Product Briefs Spotlight: Testing Tools and Sensors Q&A VW engineering chief on wireless charging at DC speeds
Gaussian Processes for Vehicle Dynamics Learning in Autonomous Racing10-08-03-00196/12/2024
In high-speed autonomous racing, it is necessary to have an accurate racecar vehicle dynamics model in order to push the vehicle closer to its limits. The choice of the dynamics model has to be made by balancing the computational demands in contrast to model complexity. Learning-based methods, such as Gaussian processes (GP)-based regression, have shown promise toward approximating the vehicle dynamics model. In particular, such methods use a simplified model structure that is easy to tune and then use GP to model the mismatch between the output of the simple model and observed system dynamics. However, current GP approaches often oversimplify the modeling process or apply strong assumptions, leading to unrealistic results that cannot translate to real-world settings. This article presents a comprehensive GP-based design for modeling the dynamics of an autonomous racing car. We do so with high-fidelity simulation data, a 1/10-scale autonomous racing car platform, and a full-scale
Ning , Jingyun, Behl, Madhur
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