1.

0 HUB DESIGN
The wheel hub assembly make is possible for you to have a smooth and
hassle-free driving experience. The hub is directlyconnected to the wheel,

and is connected to the upright. The upright is to remain stationary

relative to the chassis while the hub is to rotate with the wheel. This is
done by placing a bearing between the hub and upright. Typically a
spindle is pressed into the upright and does not rotate and a bearing is
pressed into the hub, and the spindle is pressed into the bearings
allowing the hub to rotate about the spindle.
Unsprung mass is the mass of the wheel, hub, rotor, caliper, uprights,
spindle, and brake pads.It is important to reduce unsprung mass in
order to increase acceleration. The greater the unsprung mass, the
slower the acceleration.

1.1 PREVIOUS CAR HUB DESIGN

Our previous car utilized wheel hub made of mild steel. Mild steel provided
strength to hub against bending during cornering and bump situations and
resisting against torsion during braking.The total mass of the wheel hub
excluding the bearing was -------------kg ,which consisted of --------% of our
total cars mass. Although the previous design has worked very well in terms
of strength but it had following major issues which became important design
points for the future design :

The wheels hubs were very heavy

The brake rotors once fixed could not be removed if in case it os
damaged.
The outer diameter was large which restricted us to use bearing of
larger dimension adding more weight .

1.2 SCOPE
1. Reduce upsprung mass by using aluminium 7 series alloy for
manufacturing the wheel hub which has desity 2700------(verify)(approx
one-third of mild steel)

2. Optimising the outer diameter and the thickness of wheel hub

such that it is strong enough bear all the loads ,bending,barking
force and torsions keeping the mass minimum.

3. Reduce the outer diameter of hub which ultimately reduces the

mass of bearings.
4. Provision for the brake disc to be removable and/or use of
floating brake disc.

1.2.1 USE OF ALUMINIUM 7 SERIES

following are the advantages of the using aluminium 7 series material :

This would reduce the weight of the wheel hub by a by more

than half of the previous hub.
7 series is much harder than any of its predecessor series(1 - 6)
due to larger amounts of zinc and magnesium
In general, aluminum such as 7075-t6 does not require heat
treating after welding.
Folllowing are the disadvantages of using aluminium 7 series material :

Though harder but it has very weak surface strength which is a

major drawback when aluminium hub and steel CV tripod comes
into contact. This contack may wear the surface of tripod housing
reducing its life and strength.
The 7000 series is a little tougher to machine compared to other
aluminium alloys and tends to be more free machining.
Aluminium 7000 is costlier than other alloys .

1.3 DESIGN APPROACH

1.3.1 FORCE CALCULATIONS

1.3.2 RESULTS

1.4 DESIGN PROCESS

Before the design of the hubs can commence it is necessary to choose

how it will be manufactured and from what material, since this is fundamental
to the design concept. There is a choice of two methods to manufacture the
hub available.
The first method is use of mild steel, as was used for the hubs on the K3 car,

and the second is machined from aluminium. This meant that an

investigation into which method would be most practical needed to be
conducted. The investigation looked at the availability and associated cost of
the resources for the two methods and if there was any preferences to best
deliver the aims discussed in the performance section. The deliverable from
the investigation was a recommendation based on the pros and cons of both
methods.
The decision was taken to machine the uprights from aluminium 7000 series
with the recommendation from the investigation. The reasons for taking this
decision were that it provided a cheap option with available manufacturing
resource, which is important within the tight budget, and that it gave good
dimensional accuracy and the best option to provide design freedom to
minimise mass.

1.4.1 INITIAL DESIGN

The hubs main duty is to prevent excessive deflections, particularly in

bending. In torsion, which is mainly experienced during braking,
excessive deflections can cause excessive fatigue in the hub as well as
other components
Considering the factor that smaller the outer radius of the hub lesser
would be the weight of the bearings used .The size of the CV tripod and
the minimum thickness of aluminium coressponding inner diameter
restricts us to reduce the outer diameter beyond a certain limit
.Reducing the weight of the bearing ultimately reduces the weight of
wheel assembly hence it is a very impotant factor to be considered.
This led us towards two designs :
5. Independent CV tripod housing and wheel flange
------------------------connected by a spline
6. cylindrical hollow continuous design of hub (manufactured in
single piece)

1.4.1.1 Independent CV tripod housing and wheel

flange------------------------connected by a spline

CADdiagram of design and explan

in brief
Advantages
1. The outer diameter of the hub at the bearings section can be kept

small while it is strong enough to bear forces and corresponding deformations

.
2. Inner diameter and weight of the bearing will be less compared to
previous diammeter.
Disadvantages
1. Manufacting of two parts and spline will add on the cost and time
required

1.4.1.2 cylindrical hollow continuous design of hub

(manufactured in single piece)

CADdiagram of design and explan

in brief
Advantages
7. Manufacturing will be easy and cheaper

Disadvantages
8. Mass of bearing would be more compared to splined hub design.

1.4.2 DESIGN SELECTION

After careful investigation and focusing more on cost and manufacturability of
the parts we decided we will move to splined hub design only if we fail to
optimise the diameter and thickness such that the weight of hub
assembly(hub and bearing) is less than ----------% of our previous design.
So we did calculations to find the minimum outer diameter and weight which
would successfully deliver the purpose of hub.

1.4.2.1 CALCULATIONS FOR OUTER DIAMETER AND

THICKNESS OF HUB

1.4.2.2 RESULTS AND CONCLUSIONS