When I designed the bar I did take the shear load into
account. I would like to address each
of the components separately. The flexing and the resultant stress loads are a
function of the ultimate side loading on the tires before they break loose and
how that stress is placed into the shock tower. I took into account the geometry of the front end and the bending
moment of the tower and determined the expected tension on the bar, joints,
ends and the hardware.
The center bar and end joints are not in a shear load. As the shock towers try to flex in and out
the joints and bar are in either tension or compression. I have selected the material and thread
design that will have an ultimate tensile strength that is over 20,000 psi or
20 ksi using the SI unit of measure. This is many times the maximum tensile
load that the tires can exert onto the towers.
The mounting plate was designed to also carry many times the
calculated stress. If you look at the
design, the mount base and the vertical member are welded in such a way as to
carry the shear load down the full length of the weld. In other words, the shear loading is carried
over the entire length of the weld an in the longitudinal axis of the vertical
member. The material that I selected
for these parts has very good shear and tensile strength but also have great
weld characteristics. When calculating
the shear strength of this part, even taking into account the slight reduction
in strength in the weld heat effected zone (HAZ), the ends shear and tensile
far exceed the strength needed to maintain the front end geometry of the car
without failure. According to the
United States Steel Corporation (USS) Handbook Of Plate Products, the material
we selected has an ultimate strength if 24,000 PSI or 24 KSI using the SI
measure. The smallest area of material
under load is approximately ½ resulting in that area maintaining a minimum of
12,000 pounds of ultimate strength. The
material is also very ductile and therefore not susceptible to vibration
cracking.
The last area of consideration was the selection of a 3/8
grade 8 bolt. The bolt is the smallest
part that is in shear loading. In
reviewing the ASTM table for grade 8 bolts, the 3/8 bolt has a body shear
strength of 9,940 Pound Feet (lbf) of strength. The threads are not in shear so their strength was not
calculated. With the placement and
selection of the bolt, its shear strength far exceed the calculated stress.
|
Thread Size |
Tensile Strength |
Yeild Strength (0.2% offset) |
Shear Strengtht (lbf) |
Tightening Torque |
||||
|
|
ksi |
lbf |
ksi |
lbf |
Body |
Thread |
lbf.ft |
Nm |
|
1/4 - 20 UNC |
150 |
4770 |
130 |
4130 |
4420 |
2860 |
11.7 |
15.9 |
|
5/16 - 18 UNC |
150 |
7860 |
130 |
6810 |
6900 |
4720 |
24.2 |
32.8 |
|
3/8 - 16 UNC |
150 |
11630 |
130 |
10080 |
9940 |
6980 |
42.9 |
58.1 |
In final summation we should look at the car as a
whole. The car has a total weight of
3115 pounds. The cornering loads are
primarily maintained within the structure of the cars thin sheet metal
frame. This camber truss is designed to
be a secondary stiffening devise to hold the loads that the frame cannot
maintain. The weakest part of the truss
can maintain over 9,940 pound feet of loading.
In reality the weakest part of the cars front end is the sheet metal
that is used to build the shock towers and they do not seem to have many
problems.
In the final analysis we could lift the weight of four 944s
off the ground and suspend them without a fear of failure. I hope this answers you question about the
design methodology and strength.