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

2. 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.

3. 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

4. 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

5. Result example: front and rear axle for a passenger car