Chassis Design Development Proposal for a Study Work at Tongji University Norbert Schote, Porsche AG 2012, China, Shanghai

Description of the study work for master students: Development/Design of a front and rear axle for a mid size passenger car Porsche defines the vehicle requirement and the Package boundaries (CAD Catia) Porsche will give a lecture of Chassis before the project starts A group of master students (14) will work out the concept of the chassis Axle concept definition matrix Choice of the axle concepts Design the rough axle concept in Catia Calculation the Kinematic and elastokinematic in Adams Calculation of the brake system Rough design of the main axle parts including FE-Calculation in Catia GPS Presentation of the axle concept Chinese chassis suppliers are welcome to help the students and the project Porsche will support the students during the work scope Target is, that the students get a practice knowledge how to design a chassis suspension system and get contact to some employers to get a good job in the future by an OEM or supplier.

Work scope and time schedule (1/2 year) of the chassis study work: Start of the study work project 04/2012 The Language will be English or German 1 week chassis lecture in Tongji at the beginning of the project 2,5 days of lecture at Tongji ( 2,5 x 4 x 1,5h = 15h chassis lecture of chassis design) 1 day definition of the task and questions together with interested suppliers 0,5 day, examination and discussion of results Every 2 weeks there will be for 2 hours a telephone or video meeting Agenda prepared by Tongji Questions, calculations, interim reports or CAD data must be send 1 week before Work scope for front axle (same in rear axle, in sum 14 students and two tutors): 1 tutor team leader 1 student axle concept CAD Catia 1 student Adams calculation kinematic and elastokinematic 1 student part design and calculation steering gear box and steering column (only front axle) 1 student part design and calculation of subframe/links 1 student part design and calculation knuckle, wheel, hub, bearing 1 student part design and calculation spring/damper/stabilizer 1 student part design and calculation brake system The master students must have a good English or German language, has take part in the chassis lecture, must be well trained in CAD Catia (CAD Kinematic, CAD GPS calculation) and in ADAMS The students should contact and inform them also by some interested suppliers of the different parts with (if possible) a visit to the suppliers and try to get support from the suppliers Workshop and Interim report 07/2012 together with the suppliers End of the project and presentation to the professor, Porsche and suppliers 10/2012 at Tongji and, if desired, together with the next 3 days chassis lecture in Tongji The best 2 student of front and rear axle will get 1/2 year a practice semester in Germany at Porsche chassis development

Work scope of the students: All: choose information of Benchmark cars , Bibliographie, take part in Chassis lecture 1 student team leader Responsible for Organization of the work scope, meetings, contact to suppliers, summary report, the work scope plan, part list, axle weight, costs and has the overview about the project, 1 student axle concept CAD Catia responsible for the axle concept, wheels and rims, assembly and package of all parts 1 student Adams calculation kinematic and elastokinematic Responsible for the kinematic and elastokinematic of the axle, forces to the parts 1 student part design and calculation steering gear box and steering column (only front axle) Responsible for the design and calculation of the steering system (steering ratio, steering forces, ackermann angle, tierod design and FE-calculation) Contact supplier for steering gear box and tierod, steering column 1 student part design and calculation of subframe/links Responsible for main structure part, subframe, and the links with bushings, make the design of the parts, choose the material, calculate the stress and optimize the part, choose the bushings and ball joints together with a supplier Contact supplier for welded sheet metal parts, casting parts, forged parts, ball joint suppliers, bushing suppliers 1 student part design and calculation knuckle, wheel, hub, bearing Responsible for the knuckle module, design and choose the tire, wheels, make the wheel envelopment, choose the bearing/hub system, design the knuckle , choose the material, make the FE-calculation of the knuckle , choose and calculate the drive shaft Contact suppliers for drive shaft, bearings, hubs, casting parts in steel and aluminium, forged parts (alu or steel) 1 student part design and calculation spring/damper/stabilizer Responsible for the design and calculation , contact to the supplier, calculate the first setup, the wheel travel Contact suppliers for springs, damper , stabilizer, stabilizer rods, stabilizer bushings 1 student part design and calculation brake system Calculate, choose and design the brake system, caliper, brake disc, parking brake including the brake booster, pedal ratio Contact suppliers for brake systems, booster, parking brake

Result example: front and rear axle for a passenger car