This thesis deals with the design of steering holder for a race car in the category Formula Student using topology optimisation and analysis of this design. The objective of this thesis is gaining knowledge about topology optimisation and application of this knowledge to the design of a replacement of the steering gearbox and its holder.

This thesis deals with the design and production of wheel control holders for the right front wheel of the formula Dragon 4 of TU Brno Racing team. In the theoretical part, the Formula Student competition is described, including the steering holders themselves and description of their function and location. Later the analysis of aluminium and its alloy was made, including description of the CERTAL material of which the holders were made. The practical part includes the design of prototype holders in the Autodesk Inventor CAD software, the design and application of machining strategies in the PowerMILL CAM software. Further, the practical part includes production on milling machines at the MCV 754 QUICK and DECKEL MAHO DMU 50 machining centre. At the end, the dimensional analysis of the part is performed, manufactured holders were compared to the CAD model of the given components and the technical and economical evaluation of the production was made.

Diploma thesis deals with a design and manufacture of oil cooler by technology Selective Laser Melting for Formula Student. The main goal of the design is to ensure optimal oil circuit cooling at a minimal mass. The design of manufactured oil cooler is based on a plate heat exchanger concept with optimized intakes by CFD simulations and heat exchange body with fins of thickness 0.17 mm. An analytical model was created. SLM process parameters were optimized for a thin walls printing, Subsequently, a fabrication of testing parts was finished for measuring pressure drops and performances of micro heat exchangers. Results were used for an accuracy improvement of the analytical model and for consequent optimization of heat exchange surface. Afterwards optimization was executed for inlets and outlets by using flow simulations. A prototype was built and verified on a test stand. Performance of the designed oil cooler is 4.5 kW for race mode, where temperature drop of oil circuit is 22 °C. The lightweight design weighs 320 g, which reduces more than 47 % of a current oil-air cooler weight. Furthermore, a centre of gravity is decreased by designed placement of the cooler.

Master’s thesis focused on design and construction of front uprights for Formula Student racing car. Topology optimization and FEM analysis will be used to design the uprights with higher stiffness and minimal weight difference compared to the last model. In the FEM analysis loads will be applied from wheel side and from suspension side. Design of the upright then will be compared to the previous designs especially to safety factor, weight and cost.

The topic of this master´s thesis is the design of adaptive damping algorithm for the prototype magnetorheological dampers, which are used for Formula Student vehicle. The prime output is the development and optimization of the control algorithm which included usage of the MBS software and real data from race track. Temperature compensation to supress the effect of dynamic viscosity of magnetorheological fluid due to the increase in operating temperature and testing of the vertical dynamic of the car on 4 - post test rig was realized as well. The main goal was to obtain better control of the car in transient situations and increase usability of tires via changes in damping based on actual conditions and status of the vehicle.

The main goal of this thesis is to obtain lateral parameters of the Magic Formula tire model of a tire commonly used in Formula Student competition. Both the author and the supervisor of the thesis know the tire name and its specification, but the research company that did the tire testing and provided me with the date prohibits sharing this of data publicly, so the tire designation is not mentioned in this thesis. The first chapter covers main theoretical facts related to a tire, briefly describes some of the tire models and shows possibilities how to determine tire characteristics that are used in a tire model. The thesis describes how to process raw tire data measured during a laboratory experiment using scripts created in Matlab software. The inputs variables are slip angle, lateral force, normal force and inclination angle. Raw data are splitted into parts, main coefficients of the Magic formula model (B, C, D, E, Sh, Sv) are calculated and subsequently the lateral parameters are obtained using least square method to fit parameters into the measured data. The works gives two main outcomes. The first output is a set of Matlab scripts that can be used to determine lateral parameters of any tire that has the same input data format as presented. A TIR file of the Formula Student tire in case of lateral slip is the second result of the work. This can be used for vehicle dynamics simulation of Formula Student racing car. The thesis also offers a comparison between parameters, which I calculated, and those gained thanks to Optimum Tire software by Calspan research company. Additionally the work shows the effect of load and inclination angle on lateral force.

The aim of thesis is to devise the body due to the current model in the 3D software ProEngineer and given by current Formula Student competition rules. Subsequently, the model will be created for the purposes of CFD software for numerical analysis of aerodynamics. Based on this analysis, the simulation will be obtained with the coefficient of air and axles load.

The goal of this diploma thesis was to create optimalizated frame design for Formula Student/SAE. Basic requirements were, that new design must meet the newest Formula Student/SAE rules and other various requirements. In the thesis are built up an overview of most important rules and also an overview of previous frame designs. Next are described design process of the new frame and its stress analysis in FEM software. Main attention is given to analysis of torsional stiffness. The results of analysis are compared to previous frame designs and to parameters of Formula Ford. There are also given recommendations and other possibilities for further frame design development.

In this thesis, the author deals with structural design of lifting unit for the formula car. First, he searches in the currently used solutions, followed by selection of appropriate accessories, a preliminary analytical calculation and stress analysis model. In the last part, there is made economic and weight balance.

This diploma thesis deals with description of the design of the rear of the vehicle structure of Formula Student processed by using a 3D CAD system. Formula have to fulfill all requirements Formula Student rules. The requirements and rules are given by building of engine and other considered engine components. The final version of the design of the rear part is assembled with the supplied front and the computational model is created to simulate the torsional stiffness of the FEM system. Another analysis model is created for a foreign supplied frame construction. Both of these frames are in terms of torsional stiffness evaluated and mutually compared. There are also mentioned selected Formula Student rules and overview of the formula frames and their overview.