Applying FEA and MBD Analysis for a Racing Car Conversion

Certification to race in a given group requires a safe and homologated vehicle. In this context, an Audi A3 is converted to a racing car. For providing passenger safety, a T45 carbon steel roll cage is designed and assessed via FEA under different loading scenarios. In addition, a redesign of the disc brake via a heat transfer simulation followed by a thermo-mechanical stress analysis showed that at a velocity of 150 Km/h, the maximum temperatures attained by the original and modified disc brakes are 300°C and 225°C respectively. Moreover, a suspension system is designed via multi-body dynamics analysis to give solace for the driver and absorb the shock. Through trial and error, a coil over with a stiffness of 80 N/mm and a damping coefficient of 0.3 N.s/mm is selected. Finally, the engine is homologated by modifying several parameters in order to increase power such as bore, stroke, and valves. The total cost of the homologation is around 10,000 $. In conclusion, this work provides a comprehensive roadmap for those aiming to convert regular vehicles into racing cars. By outlining key processes such as structural safety upgrades, brake system optimization, suspension tuning, and engine modifications, this study serves as a detailed guide for homologation. These modifications, performed on the Audi A3, demonstrate a clear approach to achieving competitive racing standards while balancing performance, safety, and cost-effectiveness.