K. Daubach, A. Gummel, L. Kohns, E. Kerscher
February 1, 2016
As part of the Formula Student, students independently built new racing cars every year which compete in various disciplines. The Kaiserslautern Racing Team, founded in 2007, has developed and constructed a racing car under Formula Student regulations every year since their foundation. At first, vehicles with combustion engines were built, until in season 2011/2012, the change to electric engines was realized. One of the main objectives for the second electric vehicle (season 2012/2013) was a weight reduction by 100 kg, which required adjustments in all components. For the chassis, this meant a change from 13 to 10 inch rims which were to be bought from a commercial vendor. A three-piece rim from a US vendor was purchased. Since the installed rim stars showed excessive manufacturing tolerances, for the first time, self-constructed stars were produced and used with the purchased rim base. Although the rims were designed using an FEM program, as well as an high safety factor the component failed at a test run after the season. As part of the accompanying seminar to the lecture on damage analysis at TU Kaiserslautern, the cause of the rim failure was investigated. Here, the damage analysis was performed under VDI policy 3822.