The Design and Service Life’s Research of Formula Student Racecar Wheel System Structure Based on Spline Connection

The wheel system is an important part of the chassis structure, involving suspension, transmission, braking, etc. The wheel system is the bridge between the racecar and the ground through the tires, and it is the unsprung mass of the whole racecar, which is prone to failure under extreme working conditions with severe loading. Therefore, it is of great importance to do research on its lightweight, stability, and service life, which can improve the chassis dynamics, transmission stability, and safety level of the racecar. This paper mainly focuses on the design of the racecar wheel system based on spline connection and research on the service life of the spline, including how to determine the spline parameters, surface treatment process, and the influence of the rim center nut preload on the spline. Then, combine with lightweight consideration, to determine the suitable structure design parameters of the spline. The safety factor is more than 1.8, the service life of the spline connection is more than 8600 km, and the weight is reduced by nearly 1.5 kg compared to conventional friction sub-designs. By analyzing the service life of the spline connection, the lightweight of the wheel system structure is improved while ensuring the service life, and the convenience of disassembly and installation is enhanced.