Design of Formula Stering PDF

Description and design of
the steering system for a

Formula Student car
Descripción y diseño del sistema de
dirección para un coche de formula
student
Autor: Daniel Nuviala Civera
Supervisor: D. Francisco Javier Martínez Gómez
Escuela Universitaria Técnica Industrial d Zaragoza
Departamento: Ingeniería mecánica
Convocatoria: Septiembre 2011

Final Project: steering system design
2009-2010
Summary
Our Project has as aim the description and design the elements of the steering
system for a formula S.A.E.
The steering system is one of the most important parts of the car because has the
task to control the car and guide by the desirable trajectory. The action starts on the
hands of the pilot and is transmitted through several elements that have different tasks
until turn the wheels. A failure on this mechanism can be fatal to the health of the pilot.
Before start to design the elements of the steering system car, we will study
different aspects that have influence on the design of the steering system.
First of all we report to the reader all about the Formula S.A.E. The aim, where
take place the race the rules and the history of the competition. We will discover the
main objective of the competition the development of young engineers because they
have to manufacture the cars themselves.
Then we study the formula S.A.E. rules and we will put on our project the rules
the more general rules and the rules directly related with the steering system in order to
design our system bear in mind these restrictions that are established by the
competition.
We will do a compilation of the general characteristics of a formula S.A.E. in

order to know more about this kind of cars comparing with a formula one car that is
known for the most of the people.
Subsequently we will study the theoretical knowledge and the technical

fundamentals and general comments about the steering in general in order to understand
better this system and applied on our formula S.A.E. In this chapter we will find out the
characteristics that must has a steering system and the geometry (Ackerman and
Jeantaud) of some elements of the system that produce the car has a different
performance on the road. Also we will study the different angles that we can give to the
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wheel and we will see the different qualities that the vehicle has depending on these
angles.
Continually we will start with the design of our steering system. We will start
this task separating the elements of the car that have influence on the design of the
steering and the elements that really make up the system.
As regards the elements of the car to take in consideration to design our system
we will study the measures of the cockpit because will be important in order to situate
the elements of the steering system. Then we will be able to start to design the elements.
We begin giving a description of the mechanism and continually we will describe the
function and the characteristics of each element. We will focus on the steering column,
the rack and pinion and the steering arms because we do the difference between the
elements that we can manufacture and design and the elements that we will buy to the
manufacturers. In order to design the elements that we will design ourselves we will use
the Solid works program which we can to draw the elements and to calculate the stress
that can support.
To finish we will calculate the budget of the project.
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Acknowledgements.
TO:
- My family because without them I could not study a career in
Zaragoza and now I could not make this project and anything.
- The teachers: Phil Storrow, Nick Burdon by his help that it has been
fundamental.
- My mates who are studing here with me and have been a great help
for me: Fco.Javier Ruiz de Erenchun, Ricardo Oltra, Pablo Tris, Ivan
Ruiz, Enrique Patiño, Tomas Vallés.
- My friends from Spain whit which I have study and I life together:
Ignacio Balet, Daniel Repollés, Diego Embid, Antonio Plaza, Jorge
Leciñena, Guillermo Grande, Ruben Cortés, Javier Roche, Iciar
Miguel, Patricia Rodriguez, Elena Garriga, Alberto Polo.
- Somo, Boulevard, Cai, Filosofia, Sinués
- Glyndwr, Wrexham.
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Contents
1. Introduction 6
1.1. Project aim 7
1.2. Importance of the steering system on a car. 8
1.3. The steering system on a common car 9
2. Aims of project 10-11
3. Review of literature 12
3.1. The competition: Formula Student 13-15
3.1.1. Formula student rules that have influence on the
steering system 15-19
3.1.2. Differences between a S.A.E. car and a formula one. 19-20
3.2. General comments about the steering 20-27
3.3. Technical fundamentals 28-37
4. Design process, results and discussions 38
4.1. Introduction. 39
4.2. Elements of the car that have influence on the steering system design. 40
4.2.1. The cockpit and seat 40-46
4.3. Calculation of the force to turn the wheels. 47-52
4.4. Description of the steering system elements 52-90
4.5. Budget 91
5. Conclusions 92-94
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6. Recommendations 95-96
7. References 97-99
8. Figures 100-103
9. Tables 104-105
10. Appendices 106-108
10.1. Glossary
10.2. Planos
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1.
Introduction.
1.1. Project aim

1.2. Importance of the steering system on a
car.
1.3. The steering system on a common car
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1.1. Project aim.
In this project we are going to carry out the study and the design of the steering
system for a car used on competition races in circuits.
Along the project we will focus in the steering system but also we will watch the
steering in a car that we can find travelling in one street in order to understand better the
performance of the steering elements in order to after focus in a formula S.A.E. which is
a car that requires a steering system more exigent due to is used on races.
By other hand we must know that we are manufacturing a steering system for a
car so we will bear in mind different elements of the car which have influence at the
time to manufacture the steering system. In this project we will do reference to the
characteristics to these parts of the car and the measures, the weight or the design.
The project will be carry out bearing in mind a lot of very different aspects as
the total cost of the project, the analysis stress and the materials to manufacture the
steering components and the design of the car carefully since there are some technical
rules which must be taken in consideration
With regards to the budget, the Formula Student stipulates that there is no a
maximum cost so I will make my project and finally I will calculate the total cost.
Once finished the single-seater will have as objective compete in the race of the
Formula S.A.E competition that/which it will celebrate in Silverstone circuit the dates
from 15th until 18th de Julio 2010.
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1.2. Importance of the steering system on a

common car.
The steering system is one of the most important parts of any car. Whether this
element is vital to the safety driver of the vehicle in question concern.
While the steering, as we have said, is important in a common car which we can
drive daily in our life, obviously is even more significant in a formula S.A.E. car since
this kind of vehicles are designed to compete in races and the objective of the team and
the pilot is always to bring the car to the limit to try to win. A failure of this mechanism
during operation of the vehicle could lead to fatal circumstances to the driver who is at
the expense of a car without control and with high velocity. As we have seen along the
history, a lot of the most serious accidents have been caused due to a failure on the
steering system with different fates for the drivers.
Although in this project we will start talking and explaining the elements of a
common car to know more about the steering in general in any car, then we focus on the
steering system for a competition car which is a little bit different that in a common car.
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1.3. The steering system on a common car
The steering system is the mechanism which has the purpose to turn the
guidelines wheels making that the pilot can guide his car along the desirable trajectory.
In order to carry out this task the pilot receive a lot of information by their eyes
and the brain send a stimulus to their hands which are the elements in contact with the
first part of the steering system, the steering wheel. Now the human work has finished it
is the time to the mechanism work. The steering system work is to transmit the angle
made by the pilot on the steering wheel across the different elements until the steering
wheels.
Steering system elements:
- Steering wheel
- Quick disconnect mechanism
- Steering column
- Universal joint
- Steering box (rack-pinion)
- Tie rods
- Ball-and-socket
- Steering arms
- Upright
- Pivot
In our project we will study the theoretically knowledge that has

influence on the steering system and basing on these fundaments we will design
and describe the steering system elements.
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2.
Aims of Project.
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A formula S.A.E. car is a car thought to compete in races. Everybody knows that
in a race or in any competition the person who take part always try to win and for that
try to put in effort as much as possible. In our project in which we are going to design
the steering system of a formula S.A.E car, the efforts supported by all the elements of
the vehicle are very hard and we keep in mind that the health of the pilot depends
directly of a good car design. Particularly when we talk about the steering of a car the
responsibility of to carry out a good design is maximum because join the breaking
system, is the principal system to control the car and so is the principal element for the
safety of the pilot.
By other hand as we can say we are going to design a car to compete in races.
However our car is destined to compete in Formula Student. This kind of competition is
thought to develop of young engineers because the students of different universities
manufacture their own cars with their own resources. Obviously these resources are
quite different than of a formula one team because the cars have not equal features. By
this reason our project will be carried out bearing in mind the following aspects: a low
budget, the formula S.A.E. rules and the time because the project must be finished on
30th of April and the race is from 15th to 18th of July in Silverstone circuit.
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3.
Review of Literature.
3.1. The competition: Formula Student
3.1.1. Formula student rules that have influence on
the steering system
3.1.2. Differences between a S.A.E. car and a formula
one.
3.2. General comments about the steering

3.3. Technical fundamentals
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3.1. The competition: Formula Student.
It can say that the formula S.A.E. has its origins
In 70´s years when different local American
Universities organized races with cars that had built
themselves with very limited resources. In a few years
it increased the number of universities that participated Figure 1. Fsae logo
in the competition so this great idea which helped the
development of young engineering students crossed to United Kingdom. In 1998 two

American vehicles and two English made a demonstration in Britain. Subsequently, the
IMechE in collaboration with the automotive company took over management of the
competition.
Nowadays, Formula Student is the most prestigious competition of its kind. This
competition seeks to bring students from 120 universities round the world in a real
experience with that for a year, design, manufacture, develop and compete with a car
like a small formula one team with all that this implies (design, finance, purchase of
equipment, assembly, testing…) With this ambitious challenge therefore is to develop
talented young engineers to develop in the professional world
Figure 2. Formula Student logo
There are restrictions on different aspects, so students must demonstrate

creativity and all their ingenuity to get the project forward. The challenge of designing
the car not only has restrictions as to manufacture car parts but also the reliability of the
project, so students should take the vehicle to be marketed with an annual production of
1000 units per year
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Cars will be evaluated in a series of both static and dynamic tests to see the
performance of the car.
Statics events and maximum scores:
Technical inspection ---------------------------------------- no points

Presentation -------------------------------------------------- 75 points
Design -------------------------------------------------------- 150 points
Cost and manufacturing ------------------------------------ 100 points
Dynamics events and maximum scores:
Acceleration -------------------------------------------- 75 points

Skid Pad ------------------------------------------------- 50 points
Autocross ------------------------------------------------ 150 points
Fuel economy ------------------------------- ----------- 100 points
Endurance ----------------------------------------------- 300 points
Being a total score of 1000 points.
Due to my project it is about the steering of the car, although the autocross test
and at endurance test also the steering have importance because the car will have to pass
slalom tests, where really the steering is tested is at skid pad event. In this test the car
have to run in the next circuit.
Figure 3. Formula Student event
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It is possible calculate the score with the follow equation:
-1
Skid pad score = 47.5 x + 2.5
-1
Where:
Tyour: is the average of the left and the right time laps on your best lap
including penalties
Tmin: is the elapsed time of the faster car
Due to the growth and success that this event had teams eligible to participle in
formula S.A.E. American, European Formula Student, Formula S.A.E. Australia, in
Italian or Brazilian. We focus on the European formula of students and to build the
guidance system for a student of the formula that will compete in this kind of
competition, in which the race will held at Silverstone circuit (England) for provisional
dates 15 to 18 July.
3.1.1. Formula student rules that have influence on the

steering system.
We will base our design of the steering system according to the rules and
restrictions that impose the Formula Student.
There are a lot of articles about all the aspects of the car as the fuel, the noise
caused by the car, the different parts of the vehicle: cockpit, aerodynamic elements, the
fuel tank etc, different safety measures as the belt or the cockpit padding etc. But the
most general and important for our project are the next:
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- The vehicle must be open-wheeled and open-cockpit (a formula

style body) with four wheels that are not in a straight line
- The cars normally have a measure around 3 meters but the car must
have a wheelbase of at least 1525 mm. The wheelbase is measured
from the center of ground contact of the front rear tyres with the
wheels pointed straight ahead
DIMENSIONS FRONT REAR

Overall length, width, height 2815mm, 1310mm, 1025mm 2815mm, 1310mm, 1025mm
Wheelbase 1525mm 1525mm
Track 1200mm 1100mm
Table 1. Fsae rules
- The smaller track of the vehicle (front or rear) must be no less than 75
% of the larger track
- There must be no openings through the bodywork into the driver
compartment from the front of the vehicle back to the roll bar main
hoop or firewall other than that required for the cockpit opening.
Minimal openings around the front suspension components are
allowed
- Among other requirements, the vehicle´s structure must include two
roll hoops that are braced, a front bulkhead with support system and
impact attenuator, and side impact structures.
Note: the main hoop and the front hoop are classified as ``roll
hoops´´.
Main hoop: a roll bar located alongside or just behind the driver´s
torso
Front hoop: a roll bar located above the driver´s legs, in proximity to
the steering wheel.
- The engine can have a maximum of 610cc. Must be only one round
air intake of 20 mm.
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- The fuel must be of 100 octane or a maximum of bi-ethanol E-85

- It is possible to use turbo or compressor only if is an own design
- The car must be equipped with a breaking system that acts on all four
wheels and is operated by a single control
- The perimeter shear strength of the monocoque laminate should be at
least 7.5 KN for a section with a diameter of 25 mm. this must be
proven by physical test by measuring the force required to pull or
push a 25 mm diameter object through a sample of laminate and the
results include in the SEF.
Figure 4. Fsae rules
As regards of the steering restrictions:
- The steering system must be affect at least two wheels

- The steering system must have positive steering stops that prevent the
steering linkages from locking up (the inversion of a four-bar linkage
at one of the pivots). The stops may be placed on the uprights or on
the rack and must prevent the tyres from contacting suspension, body,
or frame members during the track events.
- Allowable steering system free play is limited to seven degrees total
measure at the steering wheel
- Real wheel steering is permitted only if mechanical stops limit the
turn angle of the rear wheels to (+-3) degrees from the straight ahead
position
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- The steering wheel must be mechanically connected to the front

wheels, i.e. ``steer-by-wire´´ of the front wheels is prohibited
- The steering wheel must be attached to the column with a quick
disconnect. The driver must be able operate the quick disconnect
while in the normal driving position with gloves on
- The steering wheel must have a continuous perimeter that is near
circular or near oval, i.e. the outer perimeter profile can have some
straight sections, but not concave sections, or cutout wheels are not
allowed.
- In any angular position, the top of the steering wheel must be no
higher than the top-most surface of the front hoop
- The wheels of the car must be 203.2 mm or more in diameter

- Vehicles may have two types of tyres as follows:
• Dry tyres: the tyres on the vehicle when it is presented for
technical inspection are defined as its ``Dry tyres´´. The dry tyres
may be any size or type. They may be slicks or treaded.
Figure 6. Dry tire
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• Rain tyres: Rain tyres may be any size or type of treaded or

grooved tyre provided:
1. the tread pattern or grooves were molded in by the tyre
manufacturer or his appointed agent. Any grooves that
have been cut must have documentary proof that it was
done in accordance with these rules.
2. there is a minimum tread depth of 2.4 mm
Figure 7. rain tire
3.1.2. Differences between a common car, formula S.A.E. car

and a formula one.
In order to know how is the system which we are going to design, we must to
know the characteristics of the car. We know that the car will be a vehicle to compete in
close circuits so the features must be high quality. However this car is made for
students, young engineers which manufacture the car themselves so it is not a
competition for professionals so the aim of the Formula S.A.E. is that the engineers
learn about this world.
So we can conclude that the car, will be a vehicle for a competition but with a
not very advanced features due to it is not a professional competition and with a reduce
budget.
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We will do a comparison with a formula one, the highest competition car.

The usually measures of a S.A.E. car are the followings:
Wheelbase: 1500 to 1650 mm

Track: 1200 to 1300 mm
Engine: maximum of 610 cc
Weight: around 300 kg
As regards a formula one the difference clearest difference that we can see is the
engine since a formula one has a engine of 2400 cc and reach a velocity of 340 km/h.
With this parameter we are going the difference between the two kinds of cars
analyzing the velocities that reach the two cars in the Silverstone circuit where will be
the race of formula S.A.E.
SILVERSTONE Curva velocidad de entradaFormula SAE velocidad entrada Formula 1

1 91.67 235,00
2 94.83 270,00
3 66.33 210,00
4 96.17 175,00
5 84.50 235,00
6 89.17 190,00
7 77.33 105,00
8 74.17 130,00
9 67.67 125,00
10 54.6 90,00
Table 2. Comparison between Fsae F1
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3.2. General comments about the steering.
As we can say before in this project the steering system is the mechanism which
has the task to turn the wheels in order the driver can guide the vehicle along the
desirable trajectory.
All steering system must satisfy the following characteristics:
Safety: the most important. Depend on the reliability of the mechanism

and this one depends directly on the quality of used materials.
Gentleness: it achieves with a precise assembly and a perfect greasing.

The hardness in the driving it make difficult and tiring drive the car along the
desirable trajectory. It might be caused to badly position the tyres or because
there is more friction due to the tyres are flat
Accuracy: it takes doing a neither very hard nor gentle steering. The lack
of the steering it might be caused by the next causes:
- Caused by here is too much play in the steering elements

- Caused by a differently debilitate of the right and left tyres
- Caused by the imbalance of the tyres that is the main responsible of
the shimmy
- Caused by different pressures of the right and left tyres
Irreversibility: The steering must be semi-reversible. It consists of the

steering wheel has to transmit the motion to the wheels, but these, in spite of the
land irregularities, don´t must transmit the oscillations to the steering wheel.
The semi-reversibility allows that the wheels recover their normal position with
a small effort done by the driver after turn the steering wheel.
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Kinematic conditions.
If we observe a car covering a curve, in order to do the turn correctly, the wheel
that is in the interior of the curve must turn more than the other wheel. On the contrary
the rear wheels in any time of the turn are parallels. The problem about the difference of
the distance covering by the two rear wheels it is solved thanks to a device called
differential. However in spite of the differential, always the rear wheels skid overall in
sharp curves taken fast.
In order to the car do the curve with precision it is necessary come up with a
geometric condition, known as the Ackerman principle which explain that when a
vehicle is turning he axis of all the wheels must meet in the same point which it is called
instant rotation center.
Figure 8. Ackerman principle
We can see in this picture not only the instant rotation center, also the different
angle of the right and left wheel. The wheel that is in the interior of the curve describe
an α angle bigger than the β angle described by the other wheel. It must be on this way
because on the contrary if the front wheels will be parallels will finish broken.
To obtain these angles it is used an articulated trapezium called Jeantaud

trapezium which we can show in the next picture.
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This trapezium has two parallel sides, one is the tie rod is shorter than the other
which is the front axle which is fixed and two sides whit the same length but no
parallels (the extension of the steering arms). In the next pictures we can see clearly in a
real steering system.
Figure 9. Jeantaud trapezium
The studies executes by Jeantaud established that for the turn center of the all he
wheels it will be the same, the extension of the steering arms must join with the center
of the rear axle as we can show in the next picture.
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Figure 10 Jeantaud trapezium
With all of this, we can determinate the relationship between the wheelbase, the
track and the angles of the interior and exterior wheels in a curve. So if we have the next
picture:
Figure 11. Turn radius of the wheels
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Where:
a: track
e: wheelbase
I: instant rotation center
As we can show in the picture we have obtained two rectangles triangles: one of
them is ACI and the other BDI.
From BDI:
tg α =
sin α =
cos α =
so:
tg α = e = tg α * DI
From ACI:
tg β =
sin β =
cos β =
so:
tg β = e = tg β * (a + DI)
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So now we have two equations:
e = tg α * DI (1)
e = tg β * (a + DI) (2)
From the (1) equation we find the value of DI:
DI =
and now we substitute the value on equation (2):
e = tg β * ( a + )
e = tg β a +
e = tg β ( a + )
e= ( a + e ctg α )
ctg β =
ctg β e = a + e ctg α
ctg β e – e ctg α = a
(ctg β – ctg α) e = a
ctg β – ctg α =
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This equation allows calculate for a vehicle the value of the angle β for any value
of the angle α.
We bear in mind that the Formula student rules stipulate that:
l( ) ≤ 0.36
where:
l: wheelbase
bd: front track
bt: rear track
In the specific case of Formula S.A.E. due to the characteristics of the circuits it
is normal to reduce the wheelbase the maximum as possible in order to the vehicle it
will be easier to control.
In the case of the front and rear track the measures it will be conditioned by the
next parameters:
Minor track:
- Decrease on the lateral acceleration on this wheel assembly.

- Increase of the temperature on the exterior tyre of the curve
- Higher situation of the roll center with the that really affect to the
suspension system
Biggest track:
- Difficulty to drive by and arrow zones of the circuit

- Increase on the acceleration on this wheel assembly
- Decrease of the temperature on the exterior tyre of the curve (better
distribution exterior-interior)
- Lower roll center
The election of the track has a lot of influence on the tyres because a short track
produce much hot on the exterior tyre. On contrary a long track produce on the tyres do
not reach the adequately temperature because with a low temperature the tyres it does
not work good.
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3.3. Technical fundamentals.
Figure 12. Wheels angles
Toe angle
This is an angle, or linear measurement, formed by a line drawn through the

horizontal center of each wheel relative to the center line of the vehicle. Toe can be read
as individual, or the total of two wheels on the same axle. Proper toe will reduce scuff
and improve tire life by reducing running toe to near zero.
If the pivot and the vertical axis of the wheels will be parallels, the effort to
execute it would calculate with the next equation:
C = Fr*d
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Where:
C: resistant torque
Fr: resistance to go round
d: distance of the torque
So we try to reduce this resistant torque decreasing the distance ``d´´.
Normally the distance ``d´´ although is short, exist and furthermore is necessary
that exist a resistant torque in order to give a good stability to the steering because the
wheels tend to become disorientated with the irregularities of the road the resistant
torque made that the wheels turn to in a good position
By other hand, the inclination angle causes some tendency to turn the steering in
a straight line. This angle joins the advance, provoke that the vehicle raise on the front
part of the vehicle on the interior wheel of the curve when the advance is positive or of
the exterior wheel when the advance is negative.
Due to the weight, the vehicle tends to return to the balance position
corresponding to a turn of zero degrees, contributing, the inclination, that the guidelines
wheels take again the position in straight line and keeping in this position.
Convergence divergence
Figure 13. Toe rod
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Convergence and divergence
Every longitudinal force tends to modifier the direction of the wheels. This
effect is corrected with the convergence.
When the front wheels work only as guidelines wheels (as in our case of a
formula S.A.E.), the longitudinal force produced by the resistance to go round, is on
back direction and tends to open the wheels.
The convergence depends directly on the camber angle so the total convergence
is the algebraic addition of the necessary convergence to bear in mind the effect of the
longitudinal forces and the camber angle. Then if the camber is positive, the
convergence must be also positive, if the wheels work as guidelines wheels and motor
wheels and the camber is negative, the convergence must be negative; lastly if the
wheels work as motor wheels and the camber is positive, the convergence may be
positive or negative.
The convergence is obtained modifying the length of the steering arm. This fact
made that the Jeantaud trapezium experiment a modification since when the car is
stopped the uprights are not already perpendiculars to the longitudinal plane of the
vehicle.
So we can conclude: is convenient that the convergence is the lowest possible

but a low value of convergence is not bad because produce more stability to the car that
made a driving more relaxed since the varieties on the road as a pothole tend to be
annulated due to the convergence.
As regards the divergence, as with convergence the tyres are worn down because
the wheels are not on a straight line. However when there is divergence the wheels ate
turned on the out direction of the car making easier the turn of the vehicle. The same
than the convergence if the car has not a low value of divergence it will be very difficult
to drive the car since with a short turn of the wheel the car will turn a lot.
So what is better for a formula S.A.E. car?
On a formula S.A.E. which is a competition car the pilot can sacrifice the
stability of the car in order to turn easier on a curve. By this reason, in races it can be
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used a low value of divergence but always applied on the front wheel assembly because
we applied on the rear wheel assembly the car will be very difficult to drive.
By other hand the election of convergence or divergence it depends on the

circuit because on curves the convergence does not facilitate the turn as the divergence
but on a straight line the divergence is the bad factor.
In our case the circuit where the competition take place on Silverstone
circuit. This circuit has a first part very fast with straight lines and fast curves and
a final part with slow curves where the divergence will help to the pilot. As the
most part of the circuit is fast we will choose between 0º and 1º degrees of
divergence.
Figure 14. Silverstone circuit
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Camber angle.
Caster is a line drawn through the steering axis, compared to vertical. If the axis
is tilted back at the top, the angle is positive, tilted forward is negative. Camber
improves stability, steering wheel return and cornering.
Figure 15. Camber angle
If the wheel has a inclination in the outside direction of the car the angle is
positive and on the contrary the angle is negative
Nowadays the majority of vehicles have a camber angle around 1º on their

front wheels.
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The upright supports flexure efforts equivalent to the momentum M = W*L
Where: W: weight
L: distance
The fact to change the camber has influence on the toe angle because if the
camber angle increases the toe angle decreases and vice versa.
Also this angle has a lot of influence on the tyres because an excessive value of
the camber angle produces a high wear down of the tyres. If the camber angle is positive
the wear is produced on the exterior of the tyre and with a negative angle the wear is
produced on the interior of the tyre.
The camber angle equal to the caster angle provides the steering to keep the
straight line by the cone effect. The external and internal circumferences turn in
different velocities since have different diameters and this is the same movement that a
cone will have if go round over a plane surface. As this movement is produced on both
guidelines wheels so the same force appears on each wheel doing the vehicle improve
the steering stability.
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2009-2010
Finally the suspension has a very important role regard the camber angle.
Suspension configuration Wheel displacement Camber angle Roll center
Negative
Body 0º
Positive
Body Only negative
Body Only positive
Body Only positive
Body Mainly
positive
Body Mainly
negative
Body Mainly
negative
Table 3. Camber angle
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Caster angle.
Caster is a line drawn through the steering axis, compared to vertical. If the axis
is tilted back at the top, the angle is positive, tilted forward is negative. Caster improves
stability, steering wheel return and cornering.
Figure 16. Caster angle
In a formula S.A.E. the propulsion is produced by the rear wheels so the front
axle moves on back direction a little producing instability on the steering. We can solve
this problem given a certain camber to the pivot doing the extension line of the axis
pivot cut with the displacement line in front of the wheel. With this appears an action on
the wheel that provides stability to the steering.
The caster angle can also obtain situating the pivot in front of the vertical of the
wheel axis. On both process the wheel is dragged and then it produces stability on the
front wheels. We will bear in mind in this system the effects of the direction radius and
the toe angle.
In this case only act the backward movement forces produced by the toe angle of
the pivots.
The caster angle also depends of the camber angle. If the camber is of a
considerable importance, even the caster may be negative in order to reduce the
Pg 35
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re-position effect. In fact a lot of modern vehicles when are stopped have a negative
caster.
The caster effect must not be very important since increase the turn effort. In
other hand if the caster is very intense the return of the wheel is made a very high
velocity and can produce an abnormal position of the wheel and appear oscillations.
On cars that has the engine on the back and also has a rack inside the
steering box, as in our case, the caster has a higher value being always no very
high. Normally on this kind of cars the caster angle has a value between 5º and 10º
degrees in order to avoid the instability when the car suffer an acceleration
produce by the fact to has the engine on the back.
Drift effect
When a car is in a curve, the vehicle does not continue exactly by the trajectory
that guide the guidelines wheels since due to the effect of the transversal forces which
appear on the tyres the car is displaced guiding a trajectory that form an angle with the
rim. This angle is denominated as drift angle. So the tyre drift is the change of the
trajectory produced by the out of shape of the tyre. It cannot confuse the drift with alost
of grip or with a skid. The lost of grip can produce the skid but it has not influence on
the drift. The drift depends on the velocity, the weight of the car, the pressure and the
width of the tyre and the width of the rim.
Figure 17. Drift angle
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Figure 17´. Drift angle vs transversal force
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4.
Design process
results and
discussions.
4.1. Introduction.
4.2. Elements of the car that have influence on the

steering system design.
4.2.1. The cockpit and seat
4.3. Calculation of the force to turn the wheels
4.4. Description of the steering system elements.
4.5. Budget
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4.1. Introduction.
In this part of the project we will start to explain the different functions of the
steering system elements. Once finish, we will investigate the different possible solves
to the design of each element explaining the reason of each one. We are going to do all
of this, taking in consideration the Formula S.A.E. rules and the theoretical fundaments
that we have shown in the previous chapters. On this way in the next chapter the best
solution for each element will be choose in order to a possible manufacture of the
vehicle in a future.
We have the problem that we don´t have the measures of the chassis so we are
going to do our steering system with a supposedly measures
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4.2. Elements of the car that have influence on the

steering system design.
4.2.1. The cockpit.
The criterion to design a cockpit is to create a comfortable place to the driver.

The cockpit must be sufficiently spacious to allow the necessary movements of the pilot
to have a good control of the car. By other hand the cockpit must not be excessively big
because this fact decreases the aerodynamics capacities and the acceleration due to the
car is heavier.
Figure 18. Cockpit
In our project we design the steering system so the design of the cockpit is not
our responsibility, being a task of a project in which the chassis of the car is designed.
However this part of the single-seater has influence on the steering system design so we
will do a study of a rough estimate measures that could have a Formula S.A.E. car based
on a possible pilot measures, without give much details of the cockpit design.
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2009-2010
Figure 19. arms movement for a seated man
The size of the cockpit depends directly of the measures and the position of the
driver. This position also will have influence on the gravity center of the vehicle.
The position of the pilot is based on different aspects: the comfort to the pilot as
much as possible, to improve the features of the car principally decrease the weight and
the car has good aerodynamics conditions. Bear in mind all of this considerations we
choose a normal position of the driver to this kind of competition. The pilot will be
situated near to the floor, with the legs stretched out on the front direction. By other
hand the pilot will be situated so back as possible in the cockpit in order to allow the
movements of the driver arms. As regards with the knees and the arms, will be not
totally extended. The arms will be with an angle bigger than 90º degrees with the
steering wheel and a little bit curved. The knees will form an angle nearly to 180º
degrees with the horizontal of the vehicle. Summing up a really like position that in a
formula one.
In order to calculate the approximately measures of the cockpit we will make a

study of the measures for a possible driver. We will mesh different parts of the body of
different people and finally we will do an arithmetic mean of each measure.
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Arithmetic
Distances 1 2 3 4 5 6 7 mean
Floor to knee 53 54 57 53 55 54 58 55
Knee to hip 45 52 51 49 51 50 52 50
Shoulder to elbow 31 33 32 29 32 31 32 31.5
Elbow to knuckles 33 33 37 34 35 33 35 34
Hip to head 75.5 76 79 74 76 76 78 76
Shoulder to head 28 29 31 30 30 28 29 29
Widths
Waist 34 34 36 34.5 34 34 35 34.5
Shoulder 45.5 40 44 41 42 41 42 42
Chest 25.5 28 31 26 29 27 29 28
Table 4. Measures for a pilot model
This study has been done with seven voluntaries between 22 and 26 years old,
discount the highest and lowest values of the sampling.
Now, we have our pilot model and with the position of the driver we can design
the approximately measures of the cockpit in order to design the steering system.
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The measures of the model of the pilot are the followings:
Distances:
Floor to knee: 55 cm
Knee to waist: 50 cm
Shoulder to elbow: 31.5 cm
Elbow to knuckles: 34 cm
Waist to head: 76 cm
Shoulder to head: 29 cm
Widths:
Waist: 34.5 cm
Shoulder: 42 cm
Chest: 28 cm Figure 20. Pilot model
Weight:
71 kg
Figure 21. Pilot model
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Also we will take in consideration the angles between the back of the driver with
the vertical of the cockpit, the angle of the knees with the floor of the cockpit and the
angle of the hands with the wheel so also the angles of the arms.
Angles:
Back with vertical of the cockpit: 20º degrees
Knees with the floor of the cockpit: 180º - 30º -30º = 120º degrees
Hands with steering wheel: 90º + 15º = 110º degrees
Arms: 15º degrees with the perpendicular of the steering wheel
So we are going to calculate the approximately measures of a possible cockpit

which will be designed in detail in other project about the design of the chassis.
Lateral measures of the cockpit
Figure 22. Measures cockpit
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2009-2010
With the following values for the angles:
α = 20º
β = 20º
θ = 15º
Horizontal measures:
Cos 20 = X1 = 47.6 cm
Cos 20 = X2 = 43.3 cm
Sin 20 = X3 = 26 cm
Cos 15 = X4 = 33 cm
Cos 15 = X5 = 30.4 cm
Sin 20 = X6 = 10 cm
Vertical measures:
Cos 20 = Y1 = 65.81 cm
Tg 20 = Y1’= 27.47 cm
Y1’’ = Y1 – Y1’= 43.94 cm
Sin 20 = Y2 = 43.3 cm
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2009-2010
Front measures of the car
This measure is determined with the width of the waist and the shoulders in
order the drive is comfortable at the time to drive but the most limited possible with the
purpose to make the car lighter and more aerodynamic.
The seat
As regards with the seat of the pilot the most used on this kind of competition. It is a
really good option because is light, around 2 kg and is cheap. The seat is manufactured
by hand so it will be adapted to the cockpit measures.
Figure 23. Seat
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2009-2010
4.3. Calculation of the force to turn the wheels

Once we have done the design the total elements of the steering arms we are
going to calculate the force that must to do the driver to turn the wheels.
We will study the highest value of the force to turn the wheels. This force
appears when the car is stopped and it starts the movement of the wheel.
Fr = friction force
mg = weight
FL = lateral force
N = normal
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2009-2010
The wheel rest on the floor in a surface not in a point so it appears two friction
forces as we can show in the next picture.
In the picture the big black square is a sketch of the steering arm, the red point is
the application point of the lateral force, the distance between the red point and the
middle in horizontal direction is Rs (steering arm length), the small black square is the
contact surface between wheel and floor and Fr1 and Fr2 are the friction forces that
appears in the contact surface of the wheel which are an a distance r1 and r2 of the
middle.
Fr1 and Fr2 but in different direction are equals and r1 and r2 are equals to so:
r1 = r2 = r
Now we can do the Calculations:
Σ Fx = 0; FL – Fr = 0 (1)
Σ Fy = 0; N – mg = 0 (2)
Σ My = 0; FL*Rs – 2*Fr*r = 0 (3)
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2009-2010
From equation (1) we calculate:
FL = Fr
From (2) we have:
N = mg
This kind of vehicles have a weight around 250 kg without the weight of the
driver. We take a weight of 300 kg that is an excessive weight for these cars but on this
way we establish a safety coefficient. The weight of the pilot will be 71 kg (show on
chapter 4 measures of pilot model) so we take 80 kg for the same reason that before. By
other hand the 45 per cent of the car weight is on the front wheel assembly on these
cars.
So the weight will be:
(300 kg + 80 kg)*45/100 = 171 kg
And now each wheel supports the half of this weight:
171/2 = 85.5 kg 85.5 kg*9.81 = 838.755 N
N = 838.755 N
Now we are going to calculate the Fr.
Fr = µ*N;
Where µ is the friction coefficient. On the same way than before we are going to
take a high value of µ in order to establish a safety coefficient. So we take µ = 1.
Now we calculate the friction force:
Fr = µ*N = 838.755
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2009-2010
And from equation (1) Fr = FL so:
FL = 838.755 N
It is the force that the rack has to transmit to the tie rods and these to the steering
arms to move the wheel.
Now we can calculate the torque on the pinion. To calculate the torque we use
the following equation:
T = F * rpinion
In our case we have a pinion with a diameter of 24 mm (show in chapter 4.3) so:
T = 838.755*24 = 20130 N*mm
This is the torque in the pinion and it is transmitted through the steering column
until the steering wheel.
Finally we will to calculate the necessary tangential force that must be made in
the steering wheel by the driver to turn the wheels.
T = F * Rsteering wheel
Firstly we have to calculate the steering wheel radius because our steering wheel
is not a perfect circle it has 200mm in the vertical direction and 250mm in the
horizontal direction (show in chapter 4.3).
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2009-2010
By other hand the hands of the driver will be making an angle of 30º degrees
with the horizontal direction, in the same position that ten to past in a clock.
The red point represents the position of left hand of the driver. We have to
calculate x, being r = 250/2 = 125 mm.
x = cos 30º * r = cos30º * 125 = 108.25 mm
And finally we calculate the necessary tangential force that the driver must
produce to turn the wheels:
T = F * Rsteering wheel F = T / Rsteering wheel
F=
F = 185.95 N
It is the force when the car is stopped, the moment when the force to turn the
wheels has the highest value. Also We have to bear in mind the high values of the
weight and the that we have taken in order to put a safety coefficient in the
calculations.
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With this force we can calculate if the material for the steering column is
adequate for the torque that is transmitted by the force on the steering wheel.
The steering column support torsion efforts so:
τmax =
Where:
T: torque in the steering column
R: radio columna
J: Inertia for hollow columns Π* ( )

Where: D = 18mm; d = 16 mm (show in chapter 4.3)
τmax = = 93.58 MPa
The SAE 1015 steel with which we have made the steering column supports
386.1 Mpa and we have a value of around 100 MPa so the design is correct
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2009-2010
4.4. Description of the steering system elements
In this chapter we be able to see the elements which to made up the steering
system of one car and more in detail which are used in a competition vehicle.
The weight of the car has importance on the performance of the car since
depending of the weight the car has a different performance on the road. So we can
distinguish in two parts different elements of the car: The elements which belong to the
hang weight and the other that belong to the not hang weight.
The not hang weight: is the part of the total weight of the car which is not
support by the suspension. This weight support all the disruptions of the road so we try
to reduce this weight the much as possible
- Rims
- Upright
- Brakes
- The bearings, springs and shocks absorbers (elements of the
suspension)
The hang weight: Is the weight that is supported by the suspension. This part is
the heavier part of the car.
- Steering box
- Steering column
- Steering wheel
- Chassis, engine, driver, fuel, bodywork and one part of the
suspension.
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2009-2010
Now we are going to start with the design of the elements. We can difference
between the elements that we will design ourselves and the elements which we will buy
to the manufacturers.
Elements to design Elements to buy
Steering column Steering wheel
Rack and pinion Quick disconnect device
Tie rods Universal joint
Steering arms Ball-and-socket joint
Upright
Pivot
Steering wheel
Is the element that joins the driver with the steering system in order to control of
the car. The steering wheels change according with the manufacturer since the steering
wheels can have different radius. Important characteristics on the steering wheel are the
feel and the thickness that must be comfortable to the driver. Also the shape of the
exterior radio can has different shapes trying to achieve the most comfort to the pilot.
The steering wheel joins with the steering column through a device that is called quick
disconnect device which has the function to separate the steering wheel of the steering
column in a few seconds.
On the competition world the same that on the common car the purpose of the
steering wheel is transmit a tangential force to the steering column with the most
possible accuracy. The steering wheel is inside the cockpit and it will be situated on a
correct position according with the driver.
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2009-2010
The steering wheel has three important points according with the design: the
interior diameter, the cover and the diameter.
The interior diameter is on where the pilot puts their hands and if the driver can
grab the steering wheel without problems, he will be able to do the necessary tangential
force along the curve. As Eastman Kodak studied on 1983 the value recommended for
this diameter ranges between 18 and 53 mm, however the manufacturers normally make
designs about 30 mm and usually are oval shape to improve the hold making the driving
more comfortable. So we choose this thickness for our steering wheel.
The steering wheel cover is also important because decrease the tiredness of the
driver if the friction with the gloves is high preventing the slide between the steering
wheel with the gloves of the pilot when he is turning. A good election for the cover is
suede because is hardwearing and have good friction properties when joins with the
gloves of the pilot which usually also are made of suede.
The diameter of the steering wheel determine the easily to drive the car. The
tangential force applied over the steering wheel is between 20 and 200 N (according the
studies of the Eastman Kodak 1983). This force depends on the position of the wheels
according with the pilot.
The pilot applied the force on the exterior diameter of the steering wheel so the
momentum applied on the steering column will increase if we increase the radio of the
steering wheel although the applied force have the same value. But by other a big
exterior diameter will cause problems at the time to turn it inside a cockpit that has a
limited size.
In order to adapt the steering wheel to the cockpit on a correct position the most
of the manufacturers create the steering wheels with the down part horizontal in order to
achieve more distance between the legs of the pilot and the steering wheel.
We will chose this kind of design because is a perfect model for the position
of the pilot in a competition car where the pilot is with their legs full-length save.
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Once we have established the kind of design of the steering wheel, finally we are
going to choose it.
We have three possibilities to choose the steering wheel:
Possible solution 1:
The first possibility is Sparco 015P260F:
Diameter: 260 mm
Price: 289 $
Grip: a good grip of suede
Figure 24. Sparco steering wheeel
The second possibility is Sparco 015P310:
Dimensions: 310 * 260 mm
Price: 239 $
Grip: a good grip of suede
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2009-2010
Posible solution 3:
The third possibility is OMP Indy:
Dimensions: 250 * 200 mm
Price: 240 $
Grip: black suede crown
Steering wheel selected:
Once analyze the possibilities to choose the steering wheel, finally we

have chosen the solution 3 OMP Indy because between the three possibilities it is cheap
and overall the measures are the best to adapt to our cockpit. It has 200 mm in vertical
direction and 250 mm in horizontal direction, furthermore the down part is horizontally
o allow more space between the driver with the steering wheel
Now we are going to talk about the position of the steering wheel. According
with the Formula S.A.E. rules, the exterior diameter must be down of the safety front
hoop. The most convenient at the time to fix the position of the steering wheel is to
maximize the distance with the legs of the pilot. Furthermore we bear in mind that the
arms of the driver will not be totally on a straight line making an angle with the steering
wheel bigger than 90º degrees.
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2009-2010
Figure 27. Ssteering wheel angle
In our case this angle will be = 90º + 15º = 105º (see on chapter 4 calculation
of the driver measures angle θ ).
So now with the calculations that we have done in the previous chapter, we will
be able to calculate the position of the steering wheel.
Figure 28. Measures Calculus
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Showing this picture with the approximately measures of a driver, we can situate
the steering wheel in the cockpit.
Horizontally position:
X4 + X5 + X6 = 32.84 + 30.42 + 10 = 73.26 cm
Vertically position:
Y1’’ = 43.94 cm
Checking the design:
If the diameter steering wheel in vertical position = 20 cm.
Y1’’ – Y2 – 20/2 = 15.14 cm
It is the distance of the space between the driver with the steering wheel a
good measure for the comfort of the driver
We bear in mind in this design the rule of Formula S.A.E that says: In
any angular position, the top of the steering wheel must be no higher than the
top-most surface of the front hoop.
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Quick disconnect device
For this element the Formula S.A.E. rules specify that is obligatory that a quick
disconnect device joins the steering wheel with the steering column. This device allows
to separate quickly the steering wheel from the steering column in order the pilot can
leave the car in a few seconds.
We are going to study the different kinds of devices that we can choose and
which is the best for our project. We have found two principal kinds of quick disconnect
devices.
Hex drive mechanism:
This device is called on this way because the torque of the steering wheel
is transmitted by a hexagonal joint as we can show in the picture. Generally the
steering wheel is located on the steering shaft, using a groove in the hex drive,
and is located by a spring loaded pin which locks into the groove. The steering
wheel is released from the steering shaft by punishing the pin against the spring
until a smaller diameter section of the pin, allows the steering wheel to be
removed.
Figure 30. Hex drive
The advantage of this kind of devices is the low cost, around the 100$.
However the design produces the bad working order when it is used frequently
due to the contact area is very short and starts to wear down.
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2009-2010
Gear assembly mechanism.
These devices are a more expensive alternative, but on the contrary the
torque of the steering wheel is transmitted by one gear assembly so the value of
the torque and the contact area are bigger and cause the increase the life of the
element.
We join the mechanism with the steering wheel through piece with
triangle shape in which we will put three screws.
Figure 31. Quick disconnect device
The advantage of this kind of mechanism is the long life and the
possibility to putting electrical cable though the mechanism. The disadvantage is
the high cost around 200$.
Nowadays the most frequently is the use of this last kind of

mechanism and we also will choose the gear assembly mechanism for our
vehicle.
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The first possible solution is quick disconnect device RTQ3
Price: 204.95 $
The second possible solution is quick disconnect device STRQ-1000
Price: 109.95 $
Finally our choice will be the second one because although the first
mechanism is lighter the second one because does not vary a lot the weight and is
quite cheaper.
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Steering column
This torsion bar joins the steering wheel with steering box through the quick
disconnect mechanism. This bar only support the torsion effect produced by the turn of
the steering wheel so it is not necessary a high quality steel. Also appears short
compression efforts when the pilot leaning on the steering wheel, but are insignificant.
In order to do the design of the steering column we will see the Formula S.A.E.
rules and the effort analysis.
According with the Formula S.A.E. rules the steering column cannot be one bar
with only one direction due to different aspects. One of this is the safety of the driver
since in case of accident, on a front crash, if the steering column only has on direction it
will be easy that go out in direction to the pilot being very dangerous. The other aspects
depend on the design for the comfort of the driver. Using a universal joint we can join
two parts of the steering column making an angle allowing increase the distance
between this element and the legs of the pilot and also increase the entry pinion angle
into the steering box.
Our design
Measures: we will design a steering column with a diameter of 18 mm a very

normal measure in this kind of cars and which will be fit with our steering box
perfectly. The thickness will be 2 mm since the steering column is a hollow bar.
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Material: The steering column support torsion efforts so we do not need a high
quality steel. We will use SAE 1015.
Figure 34. AISI 1015 steel
Situation: the steering column will start on the steering wheel until the universal
joint that is fixed with the chassis. Here it is produced the change of angle on the
steering column and starts the second part of the element that join the universal joint
with the steering box. The angle between the two parts of the steering column will be
δ < 180º. When we fixe the steering box and with the exact measures of the cockpit, we
will be able to calculate the angle that it always will be δ < 180 and the difference with
the horizontal between γ φ around 15º and 20º degrees being the value of φ between
15º and 20º.
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φ + (15º or 20º) = γ
Figure 35. Steering wheel situation
Figure 35’. Assembly steering wheel-quick disconnect-steering column
Universal joint
This kind of joint is very utilized on the self-propulsion industry in order to

manufacture the steering columns, keeping the torque between bars with different
angles
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The most common kind of these devices for short angles between bars is the pin
and block which works efficiently with angles bigger than 35º degrees.
Figure 36. Universal joint
The most of the universal joints for the competition require a bar of ¾ inches
with a plane final in order to transmit the torque through the join.
We will choose the Fr1820 UNIVERSAL JOINT STEEL N which cost
59.95 $
Steering box
Is the part of the steering system defining as the joint of gear assemblies that
convert the torque transmitting by the steering column on a horizontal force. In other
words in the steering box the rotational movement transmitted by the steering column is
converted on a rectilinear movement. At the same time the rack and pinion produces a
decrease on the effort executed by the pilot from the turn of the steering wheel until the
turn of the wheels avoiding on this way the extreme tiredness of the driver.
The effort necessary to turn the wheels is higher when the vehicle is stopped and
decrease in accordance with the increase of the velocity. However we can say that this
effort depends mainly on the resistance made between the wheels and the floor due to
the friction which is function of the velocity and the weight of the vehicle.
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Exist different kinds of steering box with their respective characteristics,

although in general in the competition world is used the rack and pinion. We are going
to do a brief description of the other kinds of steering box.
WORM AND SECTOR WORM AND ROLLER
Figure 37. Worm and sector Figure 38. Worm and roller
WORM AND NUT OR RECIRCULATING BALL CAM AND LEVER
Figure 39. Worm and nut Figure 40. Cam and lever
The location on the car is very significantly since the geometry formed by the
steering box, tie rods and the end of the steering arms will form the Jeantaud trapezium
which will have a lot of influence on the performance of the car at the time to drive it.
Worm and sector
In this type of steering box, the end of the shaft from the steering wheel has a
worm gear attached to it. It meshes directly with a sector gear (so called because it is a
section of a full gear wheel). When the steering wheel is turned, the shaft turns the
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worm gear, and the sector gear pivots around its axis as its teeth are moved along the
worm gear. The sector gear is mounted on the cross shaft which passes through the
steering box and out the bottom where it is splined, and the pitman arm is attached to
the splines. When the sector gear turns, it turns the cross shaft, which turns the pitman
arm, giving the output motion that is fed into the mechanical linkage on the track rod.
The following diagram shows the active components that the present inside the worm
and sector steering box. The box itself is sealed and filled with grease.
1. Sector shaft seal
2. Input worm gear and rack
3. Worm ball
4. Ball return guide
5. Worm thrust bearing adjuster
6. Locknut
7. Worm thrust bearing Figure 41. Worm and roller
8. Sector shaft
9. Input worm gear and rack
Worm and roller
The worm and roller steering box is similar in design to the worm and sector
box. The difference here is that instead of having a sector gear that meshes with the
worm gear, there is a roller instead. The roller is mounted on a roller bearing shaft
and is held captive on the end of the cross shaft. As the worm gear turns, the roller is
forced to move along it but because it is held captive on the cross shaft, it twists the
cross shaft. Typically in these designs, the worm gear is actually an hourglass shape
so that it is wider at the ends. Without the hourglass shape, the roller might disengage
from it at the extends of its travel.
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Figure 42. Worm and roller parts
Worm and nut or recirculating ball
This is by far the most common type of steering box for pitman arm systems. In
a recirculating ball steering box, the worm drive has many more turns on it with a finer
pitch. A box or nut is clamped over the worm drive that contains dozens of ball
bearings. These loop around the worm drive and then out into a recirculating channel
within the nut where they are fed back into the worm drive again. Hence recirculating.
As the steering wheel is turned, the worm drive turns and forces the ball bearings to
press against the channel inside the nut. This forces the nut to move along the worm
drive. The nut itself has a couple of gear teeth cast into the outside of it and these mesh
with the teeth on a sector gear mechanism. This system has much less free play or slack
in it than the other designs, hence why it is used the most.
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The example below shows a recirculating ball mechanism with the nut shown in
cutaway so you can see the ball bearings and the recirculation channel.
Figure 43. Worm and nut parts
Cam and lever
Cam and lever steering boxes are very similar to worm and sector steering
boxes. The worm drive is known as a cam and has a much shallower pitch and the
sector gear is replaced with two studs that sit in the cam channels. As the worm gear is
turned, the studs slide along the cam channels which forces the cross shaft to rotate,
turning the pitman arm.
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One of the design features of this style is that it turns the cross shaft 90ºdegrees
to the normal so it exists through the side of the steering box instead of the bottom. This
can result in a very compact design when necessary.
Figure 44. Cam and lever
The rack and pinion
In general
Before the appearance of the car the use of the rack and pinion was limited only
to small vehicles because the steering proved too heavy and the improvements were not
sufficiently suitable so it was necessary to make a lot of turns with the steering wheel in
order to guide the wheels on the desirable trajectory. Nowadays this problem has been
solved with the power-assisted steering.
Pg 71
2009-2010
Actually the rack and pinion is very used by the fact that is cheap and the
assembly is simply allowing the incorporation system that help on the driving as the
power-assisted steering.
Figure 45. Rack and pinion
The system is connected directly with the tie rod and this one with the wheels
having a high mechanical output. It is a great accuracy system, particularly in cars with
the motor on the front part and with front-wheel-drive since decrease enormously the
effort to do, is very smooth, and has a good recuperation and is safe.
The steering column ends with a pinion (generally helicoids) that engages
constantly with a bar that is a rack. The rack moves inside a framework that is used as a
guide and as protection of the outside agents. The rack is directly jointed with the tie
rods with the ball-socket-joints transmitting the movement to the wheels.
There are steering systems that have a power-assisted steering. This mechanism
has the task of decrease the necessary effort at the time to drive the car. On the common
cars the most used is the hydraulic system although is also used the pneumatic system or
with an electrical system in the steering column.
But in our case of a formula S.A.E. we will not use a power-assisted steering.
Pg 72
2009-2010
In our case
We have chosen the rack and pinion due is by far the most steering box used in a
car and in particular because is light, simply and cheap. For this reason, is the election
on the cars used to compete on circuits since the rack and pinion provide a lot of
information to the pilot about the track due to have not auxiliary mechanisms that limit
the feeling of the pilot.
Once transmitted the torque of the steering column through the pinion to the
rack, the longitudinal movement of the rack is transmitted to the tie rods through of an
axial ball-and-socket joint.
Inside the steering box the pinion will must be quite small and to transmit the
high efforts to move the steering the modulus must be big so it must has a few number
of teeth.
Both the pinion and the rack must be made of a high quality steel and are case-
hardened (material treatment) since have to support high efforts.
Figure 46. Rack and pinion lateral Figure 47. Rack and pinion front
Pg 73
2009-2010
Our design
In order to make the design of our rack-pinion for the steering box, we base our
work on the choice of the rack and the pinion which will produce a greater lateral
displacement of the wheels with the same turn of the steering wheel.
We start saying that our steering column has a radius of 18 mm an adequate

value for this kind of cars.
The other start point is that the rack and the pinion must be the same modulus
and the same material. A suitable material for these elements is SAE 1045 steel which is
easy to mechanize.
Figure 48. Rack and pinion SAE 1045
Pg 74
2009-2010
In the followings pictures we can show the necessary parameters of the rack and
pinion which we will operate to calculate the best possible design for our steering box.
Figure 49. Rack and pinion parameters
N: velocity of the pinion turn
V: velocity of the rack
Z: number of pinion teeth
n: number of rack teeth in one cm
In order to calculate the velocity of the rack it is used the following equation:
v =N( ) cm/sg
And to calculate the distance that advance the rack in one complete turn of the
pinion is:
d= cm
So we are going the possible design of the racks and pinions and the possible
joints of these elements.
Pg 75
2009-2010
Parameters of pinions:
Pinion 1 Pinion 2
Modulus 2 2
Z 11 12
D 27.8 28
C 22 24
E 20 20
Allowable torque (kgf.m)
bending strength 3.5 2.9
Allowable torque (kgf.m)
surface durability 1.12 1.15
Table 5. Pinions parameters
Pg 76
2009-2010
Parameters of the racks:
Rack 1 Rack 2 Rack 3

Modulus 2 2 2
N 14 46 79
Total lenght 98 303 505
B 20 20 20
C 25 25 25
D 23 23 23
Allowable force 391 391 391

(kgf) bending
strength
Allowable force 79 79 79
(kgf) surface
durability
Table 6. racks parameters
Pg 77
2009-2010
With all the parameters of the two tables, we are going to choose the best option
for our rack and pinion. The optimum design, will be that achieve a high value of the
lateral displacement of the rack. We discount the rack 3 because the total length is larger
than the width of our cockpit so it is not valid.
So:
Design 1:
Pinion 1 with rack one
We calculate the number of teeth in one cm of the rack:
n= = 0.143 teeth/cm
And now we calculate the displacement of the rack advance:
d= = = 76.92 cm
Design 2:
Pinion 2 with rack 2
We calculate the number of teeth in one cm of the rack:
n= = 0.15 teeth/cm
And now we calculate the displacement of the rack advance:
d= = = 80 cm
Design 3:
Now we calculate the displacement of the rack advance:
d= = = 73.3 cm
Pg 78
2009-2010
Design 4:
Now we calculate the displacement of the rack advance:
d= = = 83.9 cm
Now we are going to do a graphical representation:
distance rack vs turns of pinion

90
80
70
disatance cm
60
50 diseño 1
40
diseño 2
30
diseño 3
20
diseño 4
10
0
0 0.25 0.50 0.75 1
number of turns pinion
Table 7. Graph designs
As regards the velocity with the rack is moved , we can calculate as we can say
before with the following equation:
v =N( )
But in this case we are not going to do the calculations because we are looking
for the best design, and now we are interested in achieve a greater velocity of the rack
not a determined velocity only which design produce the highest value on the velocity
Pg 79
2009-2010
of the rack. So if we take any value for the velocity of pinion turn and the same for all
the designs we obtain the same result because the velocity multiply to the lateral
displacement of the rack (d = z/n) so the design with the highest value of ``d´´ also will
be the highest value of ``v´´.
Finally we can conclude that our design will be the pinion 2 with the rack 1.
Modulus Z D C E Material
Pinion2 2 12 28 24 20 SAE 1045
Modulus n Total length B C D Material

Rack 1 2 14 98 20 25 23 SAE 1045
Table 8. The design chosen
Position:
The position of the steering box will be determinate with the dimensions of the
wheel. For Formula S.A.E. we will choose a wheel for the competition with the
followings dimensions:
20.0 x 7.0 – 13 inches
If we translate to cm, we have an exterior diameter of 20 x 2.5 = 50 cm. Bearing

in mind that the steering box is joined with the wheel through the tie rods and the
steering arms at the middle of the wheel. So we can obtain the distance of the steering
box with the road and if we had the exacts measures of the cockpit we could calculate
the distance of the steering box with the cockpit floor but the project of the chassis is
studied in other project.
Finally the distance of the steering box to the road is:
50 / 2 = 25 cm
Pg 80
2009-2010
Tie rod
In our case in which we have chosen the rack and pinion for our steering box the
tie rods are the bars which join the rack with the steering arms. The join is made
through ball-and-socket joint. The connection between the ball-and-socket join and the
steering arms is thread, making possible the variation of the distance from the end of the
rack to the end of the steering arms. Then the joint secures through with nuts and
locknuts. This is used to adjust the parallelism between the wheels.
The tie rods must be made of alloyed steel since must be support the knocks to
come from the wheels through the upright and the steering arms.
Figure 50. Tie rod
Our design
Material:
The tie rods support compression and traction efforts so for this element
we will use AISI/SAE 1023 steel with a treatment of the surface in order to
protect against the corrosion.
Pg 81
2009-2010
Measures:
The formula S.A.E. stipulates that the front track must be a minimum of
1200 mm so the distance of the tie rods will define with the measure of the rack
the front track of the formula S.A.E.
Track = rack measure + tie rod measure * 2 =
We will determinate the measure of the tie rods with the team which
carry out the suspension design because they have to do the task of the design
the suspension arms and springs that will join with upright.
Now we will join the tie rod with the steering arm through a
ball-and-socket joint.
Ball-and-socket joint
The ball-and- socket joint allows the
oscillations produced by the movement of the
steering (the movement of the rack and he
steering arms are in different plane) and the
effect of the suspension (the wheels and the
steering arms oscillate with the suspension
whereas the rack is joined rigidly to the chassis).
These elements consist of three parts: one ball,
one bearing situated behind the ball in order to Figure 51. Ball socket joint
reduce the friction and the framework that contains them. The ball is connected with a
thread rod in where is connected one of the elements to articulate. The other element is
connected with another thread rod that comes from the framework.
Pg 82
2009-2010
Figure 52. Ball socket joint measures
Steering arms
The steering arms are the last part of the Ackerman quadrilateral. In his
movement, through the ball-and-socket joints, push or pull from the steering arms
which transmit the movement to the upright that is element that fix the wheel causing
finally the turn of the wheels.
As we can explain in a previous chapter and as we also can show in the pictures
we will situated the steering arms with an angle that in the stop position the extensions
of the lines that join the ends of the steering arms coincide on the center of the rear axle
according with the Jeantaud trapezium
Figure 53. Jeantaud trapezium
Pg 83
2009-2010
Our design
We thought firstly to design a upright with the steering arm include. However
we do not choose this option because with a separate steering arm the efforts are not so
concentrate in the upright. We are going to see the stress analysis for the steering arm
when the driver turns the wheel and the tie rods transmit a force to the steering arms.
The force applied in the steering arm is the force calculated previously in the chapter
4.3.
Figure 54. Steering arm in solid works
Pg 84
2009-2010
Figure 55. Stress analysis in solid works of the steering arm
As we can see in the picture the deformation is produced in the joint with the tie
rod and with the force that we have applied the steering arm support the effort correctly
because have a maximum deformation of 2.031e-002 mm
Upright
There are two kinds of uprights: the front and the rear uprights. Both are quite
different since have different tasks on the car. The front uprights turn around the pivot
and move the wheel due to the force that has transmitted the steering wheel.
Furthermore the upright have two more functions: to fix the wheel and join the wheel
with the suspension arms.
Pg 85
2009-2010
These elements must be very stiff in order to support the knocks that in
frequently occasions will be very violent but at the same time they must be sufficiently
tough in order to do not finish braked.
Our design
We have designed, as we have said before, the upright separately of the steering
arm in order to decrease the efforts on this element. By other hand we have designed the
upright in order to be light. Finally the last parameter, we are going to design the
upright inside a rim of 13 inches
Figure 56. Upright in solid works
Pg 86
2009-2010
Now we are going to see the stress analysis hen we apply the force.
Front upright
Figure 57. Stress analysis of the upright
Back upright
Figure 58. Stress analysis of the upright
Pg 87
2009-2010
The displacement
Figure 59. Displacemnet
When we apply the force on the steering arm this one transmit the force to the
upright and as we can show in the picture the maximum deflection is 8.154e-002 mm.
The assembly:
Figure 60. Assembly
Pg 88
2009-2010
Pivot
The pivot is the rotate axis of the join steering arm, upright and wheel and
furthermore the joint of the wheel with the suspension and chassis.
This element is cementated and rectified (treatments of metals) in order to make

easier the turn of the upright. The pivot is made with a high quality steel because it
supports high values of a shear force.
Depending on the suspension kind manufactured on the vehicle, it will be better

different uses of the steering mechanisms. In our case, in a competition car, the caster
must be decreased the much as possible so the pivot will be nearly perpendicular with
the floor.
Figure 61. The pivot
Pg 89
2009-2010
Wheels
This element is the last element on the steering system and the suspension
system. The tyres are supplied by the manufacturers. We choose the Goodyear as the
brand of the tyres. The tyres for 2010 that goodyear supply are the followings.
Kinds of tyres:
Slicks: 20.0 x 7.0 – 13 ``SAE´´
Figure 62. Slick tyre
Rain wheels: D*1883 20 x 6.5 – 13 R065
Figure 63. rain tyre
Pg 90
2009-2010
4.5. Budget.
The total cost of the elements which we will buy:
Price per unit Number of Total price

Elements units
Steering wheel 240 $ 1 240 $
Quick disconnect 1 109.95 $

109.95 $
Universal joint 59.95 $ 1 59.95 $
Ball-socket joint 4 16.40 $

4.10 $
Final price 426.3 $
Table 9. Budget
Pg 91
2009-2010
5.
Conclusions.
Pg 92
2009-2010
Finally we have finished our design. We have to design the steering system for a
formula S.A.E. car describing all the elements and choosing the better options to make
it and to can adapted in a total project to a car with the characteristics of Formula S.A.E.
We started the project investigating about this kind of vehicles and about the
steering system in general in a car. The first step was to know the formula S.A.E. rules
and the theoretical fundaments about the steering as Ackerman or the Jeanteaud
Trapezium. These concepts have been in mind during the design of our elements.
The elements rack and pinion, tie rods, steering arms and the upright we have
determinate the Jeantaud trapezium and we have obtained the connection between the
turn angles of the front wheels with the wheelbase and the tracks. According to Jeantaud
studies we have design the elements in order to the extensions of the lines that join the
end of the tie rods with the point where the steering arm is joined with the upright finish
on the center of the rear track in order to achieve a good performance of the vehicle.
As regards the elements, we have done the difference between the elements
which will be designed by ourselves and the elements which we will buy to the
manufacturers.
Talking about the elements which have been designed by ourselves we can say
that we have done this task basing our designs in three parameters: comfort and safety
for the pilot, improve the features of the car and the price, trying that the design is the
cheapest as possible.
To situate the steering wheel and the steering column we have make a study
between seven people in order to achieve the measures of a possible pilot. Once finish
this task, we have calculate the position of the steering wheel achieving that the pilot
drive in a good position avoiding an extreme tiredness and respecting the SAE rules that
say the top of the steering wheel must be no higher than the top-most surface of the
front hoop.
For the steering column we have calculated the torque produced in the element
when the drive applies the maximum force to turn the wheels producing fatigue effort
on the steel of 93.58 MPa and the steel chosen by our is the SAE 1015 that support until
386.1 MPa so the design for the steering column is correct.
Pg 93
2009-2010
To design the rack and pinion we had to check for a steering column with 18
mm in diameter which was the most suitable design. We needed to achieve a larger
advance distance for the rack with the same turn in the pinion. We have done four
designs with two pinions and two racks. With the first design we achieve a distance of
76.92 cm, with the second 80 cm, with the third 73.3 cm and with the fourth 83.9 cm so
we have chosen the fourth design since with the same turn of the steering wheel we
achieve a larger advance distance of the rack in consequence a high value of the wheels
turn. On this way we improve the steering system because in a curve the pilot has not to
turn a lot the steering wheel so the tiredness in the driving will decrease.
We thought to do a foundation steering arm with the upright but finally we chose
to separate in two pieces the steering arm and the upright in order to improve the
features of the car. With the first design appear a lot of efforts in the upright so we
chose separate in two pieces. As we shown in the previous chapter with our design the
upright suffer a flexion efforts but with a very short displacement for the high value of
the force, transmitted by the tie rods, which we have calculated with an excessive
weight and friction coefficient to establish a safety coefficient. The weight is a
parameter that always is important decrease as much as possible and with this design we
achieve that the upright is lighter than the other.
Finally we have shown the budget for the elements to buy to the manufacturers
and it is a total of 426.3 $ that have been chosen trying obtained low prices for each
element but satisfying our necessities.
Pg 94
2009-2010
6.
Recommendations.
Pg 95
2009-2010
From my point of view it will be interesting to continue with the design of the
upright and the steering arms in order to improve these elements trying to decrease the
weight of these elements maintaining the features and that the design of the element is
no too expensive.
By other hand this kind of cars has not power-assisted steering but it will be
interesting to decrease the force made by the driver to turn the wheels.
Pg 96
2009-2010
7.
References.
Pg 97
2009-2010
In this chapter we are going to write the web pages which have been used to
make this project:
WEB PAGES:
www.Librospdf.net/ingenieria-automovil
www.thef1.com/protagonistas/circuitos/silverstone
www.squadracorse-polito.com/en/sc-events/venueevents/1-silverstone-circuit.html
http://www.slideshare.net/gatox99x/seleccion-de-material-para-el-sistema-de-direccion-
por-cremallera
www.students.sae.org/competitions/formulaseries
www.fsae.com
www.circulaseguro.com
http://www.tecnun.es/fstudent
http://www.formulastudent.com/
http://www.motorweb-es.com/ formulaSAE.htm
http://www.mimecanicapopular.com/
http://www.autocity.com/
http://www.imeche.org
http://www.auto-publitest.com/SP1/FamProd_Geometria.htm
http://grupos.emagister.com/debate/formula_sae/6745-304276
www.khkgears.co.jp
http://www.scribd.com/doc/2561082/Tema8Torsion
www.beldenuniversal.com
www.streetsideauto.com
www.sparcousa.com
Pg 98
2009-2010
www.ompracing.it
www.tarsa.biz/pagina_nueva_13.htm
www.efunda.com
www.scribd.com
www.antonio-Ida.blogspot.com/2009/05/pinion-cremallera.html
www.truechoice.com
www.substech.com
www.carbible.com/steering_bibles.html
www.km77.com
http://www.hoosiertire.com/Fsaeinfo.htm
http://www.racegoodyear.com/tires/sae.html
BOOKS:
José Duran Abarca, 2001, La dirección. Ceac
J.N. Alonso, 1998, Técnicas del automóvil. Paraninfo
P.Luque, D.Alvarez, C.Vera. Ingeniería del automóvil. Thomson
Simon McBeath, 1999, Competition car preparation. Haynes publishing
Hans B. Pacejka, 2002, Tyre and vehicle dynamics. BH.
Carroll Smith, 1984, Engineer to win. Motorbikes international
J. Rempell, H. Stoll, J.W. Betzler, 1986, Theautomative chassis. BH.
Catalogue Demontweeke
Pg 99
2009-2010
8.
Figures.
Pg 100
2009-2010
Figure 1. Fsae logo 13
Figure 2. Formula Student logo 13
Figure 3. Formula Student logo 14
Figure 4. Fsae rules 17
Figure 7. rain tire 19
Figure 8. Ackerman principle 22
Figure 9. Jeantaud trapezium 23
Figure 11. turn radius of the wheels 24
Figure 12. Wheels angles 28
Figure 13. Toe rod 29
Figure 14. Silverstone circuit 31
Figure 15. Camber angle 32
Figure 16. Caster angle 35
Figure 17. Drift angle 36
Figure 17’ Drift angle vs transversal force 37
Figure 18. Cockpit 40
Figure 19. arms movement for a seated man 41
Figure 20. Pilot model 43
Figure 21. Pilot model 43
Figure 22. Measures cockpit 44
Figure 23. Seat 46
Figure 24. Sparco steering wheeel 56
Pg 101
2009-2010
Figure 27. Ssteering wheel angle 58
Figure 28. Measures Calculus 58
Figure 30. Hex drive 60
Figure 31. Quick disconnect device 61
Figure 32. quick disconnect device 62
Figure 33. quick disconnect device 62
Figure 34. AISI 1015 steel 64
Figure 35. Steering wheel situation 65
Figure 35’. Assembly steering wheel-quick disconnect-steering column 65
Figure 36. Universal joint 66
Figure 37, worm and sector 67
Figure 38. worm and roller 67
Figure 39. Worm and nut 67
Figure 40, Cam and lever 67
Figure 41. Worm and roller 68
Figure 42. Worm and roller parts 69
Figure 43. Worm and nut parts 70
Figure 44. Cam and lever 71
Figure 45. Rack and pinion 72
Figure 46. Rack and pinion lateral 73
Figure 47. Rack and pinion front 73
Figure 48, Rack and pinion SAE 1045 74
Pg 102
2009-2010
Figure 49. Rack and pinion parameters 75
Figure 50, Tie rod 81
Figure 51. Ball socket joint 82
Figure 52. Ball socket joint measures 83
Figure 54. Steering arm in solid works 84
Figure 55. Stress analysis in solid works of the steering arm 85
Figure 56. Upright in solid works 86
Figure 57. Stress analysis of the upright 87
Figure 58. Stress analysis of the upright 87
Figure 59. Displacement 88
Figure 60. Assembly 88
Figure 61. The pivot 89
Figure 62, Slick tyre 90
Figure 63, Rain tyre 90
Pg 103
2009-2010
9.
Tables.
Pg 104
2009-2010
Table 1. Fsae rules 16
Table 2 Comparison Fsae and F1 20
Table 3 Camber angle 34
Table 4 Measures pilot model 42
Table 5 pinion parameters 76
Table 6 Rack parameters 76
Table 7 Graph designs 79
Table 8 Design chosen 80
Table 9 Budget 91
Pg 105
2009-2010
10.
Appendices
10.1. Glossary.
10.2. Planes
Pg 106
2009-2010
10.1. Glossary.
• Wheelbase: it is the distance between the front track and the rear track
• Track: it is the distance between the pivots of the right and left wheels
• Roll center: is the notional point at which the cornering forces in the
suspension are reacted to the vehicle body
• Torsion bar: is a bar that supports torsion efforts. These efforts are
produced by a tangential force in one point that is not the center on a
circular bar.
• Single-seater: it is a car in which only can be one person. Normally in this
kind of cars the place where drive the pilot is called cockpit
• Friction: force that appears contrary to the movement due to the contact
between two surfaces.
• Gear assembly: It is a mechanism in which two elements transmitte a
movement between them through, a part of the pieces that is called teeth.
• Power assisted steering: it is a mechanism used on the steering system to
make the turn on the steering wheel easy because the driver has to do less
force. Principally there are two kinds: hydraulic and electrical.
• Front wheel drive: is a form of engine/transmission layout used in motor
vehicles, where the engine drives the front wheels only. Most modern
front-wheel drive vehicles feature a transverse engine, rather than the
conventional longitudinal engine arrangement generally found in rear-
wheel drive and four-wheel drive vehicles
Pg 107
2009-2010
• Front wheel assembly: is the joint of the elements of the front part of the
car.
• Rear wheel assembly: Is the joint of the elements of the rear part of the
car
• Not hang weight: It is the part and elements of the car weigh that are not
supported by the suspension system.
• Hang weight: it is the part and elements of the car weight that are
supported by the suspension system.
• Torque: is the tendency of a force to rotate an object about an axis
fulcrum, or pivot. Just as a force is a push or a pull, a torque can be thought
of as a twist
• Rim: It is the part of the wheel generally made of aluminium or steel that
is inside of the tire supporting it.
• Instant rotation center: also called instantaneous centre, for a plane figure
moving in a two dimensional plane is a point in its plane around which all
other points on the figure, for one instant, are rotating. This point itself is
the only point that is not moving at that instant.
• Kinematic: is the science that studies the movement of a particle on the
space.
• Dynamic: is the science that study the movement of a particle produced
by a force
• Aerodynamic: is a branch of dynamics concerned with studying the
motion of air, particularly when it interacts with a moving object.
Aerodynamics is a subfield of fluid dynamics and gas dynamics, with much
theory shared between them
Pg 108
1 2 3 4 5 6
62,210
34,055
35,857
A A
14
11,296
34,800
5
40
25
5
192,501
14
73,750
96,583
B B
45,286
51,301 45,333
15
11
19
20
20,857
32
30
56,557
C C
117,883
24,143
SI NO SE INDICA LO CONTRARIO: ACABADO: REBARBAR Y

NO CAMBIE LA ESCALA REVISIÓN
LAS COTAS SE EXPRESAN EN MM ROMPER ARISTAS
ACABADO SUPERFICIAL: VIVAS
TOLERANCIAS:
LINEAL:
ANGULAR:
NOMBRE FIRMA FECHA TÍTULO:

DIBUJ. Daniel Nuviala Civera
VERIF. Phil Storrow upright

D
APROB.
FABR.
1
CALID. MATERIAL:
A4
N.º DE DIBUJO
1 2 PESO: ESCALA:1:5 HOJA 1 DE 1

1 2 3 4 5 6
36
21
A R17 A
14 25
30,129
58,669
26,644
23
,24
0
59,915
166,331
36
B 33 B
32,001
22
R 11,500
C C
15
42
SI NO SE INDICA LO CONTRARIO: ACABADO: REBARBAR Y
NO CAMBIE LA ESCALA REVISIÓN
LAS COTAS SE EXPRESAN EN MM ROMPER ARISTAS
ACABADO SUPERFICIAL: VIVAS
TOLERANCIAS:
LINEAL:
ANGULAR:
NOMBRE FIRMA FECHA TÍTULO:

DIBUJ. Daniel Nuviala Civera
D
VERIF. Phil Storrow Steering arm
APROB.
FABR.
2
CALID. MATERIAL:
A4
N.º DE DIBUJO
1 2 PESO: ESCALA:1:2 HOJA 1 DE 1

1 2 3 4 5 6
A A
98.0
B B
20.5 23.0 25.0
C C
UNLESS OTHERWISE SPECIFIED: FINISH: DEBUR AND

BREAK SHARP DO NOT SCALE DRAWING REVISION
DIMENSIONS ARE IN MILLIMETERS
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:
NAME SIGNATURE DATE TITLE:

DRAWN Daniel Nuviala Civera
D
CHK'D Phil Storrow Rack
APPV'D
MFG
3
Q.A MATERIAL:
DWG NO.
A4
1 2 WEIGHT: SCALE:1:1 SHEET 1 OF 1

1 2 3 4 5 6
A A
29.5 20.0
24.0
B 28.0 B
18.2
C C
UNLESS OTHERWISE SPECIFIED: FINISH: DEBUR AND

BREAK SHARP DO NOT SCALE DRAWING REVISION
DIMENSIONS ARE IN MILLIMETERS
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:
NAME SIGNATURE DATE TITLE:

DRAWN Daniel Nuviala Civera
D
CHK'D Phil Storrow Pinion
APPV'D
MFG
4
Q.A MATERIAL:
DWG NO.
A4
1 2 WEIGHT: SCALE:1:1 SHEET 1 OF 1

2009-2010
``If you have the control, you are not in the limit´´
Ayrton Senna
Pg 109

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Description and design of

the steering system for a

Descripción y diseño del sistema de

dirección para un coche de formula

Autor: Daniel Nuviala Civera

Supervisor: D. Francisco Javier Martínez Gómez

Escuela Universitaria Técnica Industrial d Zaragoza

Departamento: Ingeniería mecánica

Convocatoria: Septiembre 2011

We will do a compilation of the general characteristics of a formula S.A.E. in

Subsequently we will study the theoretical knowledge and the technical

To finish we will calculate the budget of the project.

- Somo, Boulevard, Cai, Filosofia, Sinués

1.1. Project aim 7

1.2. Importance of the steering system on a car. 8

1.3. The steering system on a common car 9

2. Aims of project 10-11

3.1. The competition: Formula Student 13-15

3.1.1. Formula student rules that have influence on the

steering system 15-19

3.1.2. Differences between a S.A.E. car and a formula one. 19-20

3.2. General comments about the steering 20-27

3.3. Technical fundamentals 28-37

4. Design process, results and discussions 38

4.2.1. The cockpit and seat 40-46

4.3. Calculation of the force to turn the wheels. 47-52

4.4. Description of the steering system elements 52-90

10. Appendices 106-108

1.1. Project aim

1.1. Project aim.

1.2. Importance of the steering system on a

1.3. The steering system on a common car

Steering system elements:

In our project we will study the theoretically knowledge that has

3.2. General comments about the steering

3.1. The competition: Formula Student.

It can say that the formula S.A.E. has its origins

In 70´s years when different local American

Universities organized races with cars that had built

themselves with very limited resources. In a few years

it increased the number of universities that participated Figure 1. Fsae logo

in the competition so this great idea which helped the

development of young engineering students crossed to United Kingdom. In 1998 two

Figure 2. Formula Student logo

There are restrictions on different aspects, so students must demonstrate

Statics events and maximum scores:

Technical inspection ---------------------------------------- no points

Dynamics events and maximum scores:

Acceleration -------------------------------------------- 75 points

Being a total score of 1000 points.

Figure 3. Formula Student event

It is possible calculate the score with the follow equation:

Skid pad score = 47.5 x + 2.5

3.1.1. Formula student rules that have influence on the

- The vehicle must be open-wheeled and open-cockpit (a formula

DIMENSIONS FRONT REAR

- The fuel must be of 100 octane or a maximum of bi-ethanol E-85

Figure 4. Fsae rules

As regards of the steering restrictions: