Design of a Formula SAE Car Frame Team: Suspension...

Suspension Team:

Michael Gorbach

Joe Salemi

Tyler Welch

Brad Werner

Design of a Formula SAE Car

Budget

Deliverables

Frame Team:

Adam Camp

Brock Bursott

Matt Morge

Jacob Holderbaugh

Drivetrain Team:

Andrew Ebert

Andrew Farkas

David Novalinski

Hans Vik

Ragan Van Hecke

Budgeted Allocated Available

Drivetrain & Engine $ 2,075.00 $ 2,500.64 $ (425.64)

Suspension $ 1,722.48 $ 1,963.90 $ (241.42)

Frame $ 1,890.00 $ 1,290.80 $ 599.20

Systems $ 640.00 $ 640.73 $ (0.73)

Misc $ 3,610.00 $ 3,120.26 $ 489.74

Total $ 9,937.48 $ 9,516.33 $ 421.15

Introduction The objective of this project is to design and construct a functioning FSAE

vehicle. The vehicle will comply with all rules set by the SAE organization and

the additional rules set by the project client and adviser.

Gantt Chart

Tested vehicle compliant with all

rules

CAD models on a storage device

(SolidWorks, Pro/E, Racing by the

Numbers)

Documentation of calculations for

design validation

Our deadlines were: November 14th suspension points

and forces and final drive ratio

January 2nd welded frame

March 14th rolling chassis

April 3rd operational car

May 1st fully tested car

Design Tasks By Team

Our goals for this year were to: Spend less than $10,000

A wet weight under 470 pounds

An acceleration time under 4.0 seconds

Skid pad time of les than 6.0 seconds

Comply with all FSAE rules and regulations

Suspension Drivetrain Frame Suspension system

Uprights

Brake system (to reservoir)

A-arms

Steering geometry

Modeling of the suspension

system to assess its performance

Rear Box

Weight management

Correlated acceleration model

Final Drive Ratio

CVT Tuning

Secondary support(s) and shaft

Chain and chain tensioner

Axles

Differential support

Cooling system

Data Acquisition

Wheel Centers

Validate last year’s

frame

Validate SolidWorks

methodology for tubing

and welded joints

Pedals

Impact attenuator

Frame

Design Analysis By Team Frame

Weight (lbs)

Actual (mm)

Solidworks (mm)

10 15.24 13.79

25 38.1 34.47

35 53.98 48.25

Drivetrain Engine Data:

73 hp @ 6,800 RPM

Acceleration Model

Sprocket Design

Yield strength: 275 MPa

Max Stress: 24.5 MPa

Steel space frame specs

Weight: 66 lbs

Length: 91.25 in

Height: 47.75 in

Width: 35 in

Bottom width: 17 in

Suspension Rear Suspension Assembly

Front Suspension Assembly

Steering Assembly

Front Pushrod Assembly

Rear Pushrod Assembly

Body

Engine mount

Cockpit

Responsible for the

CAD files of the car

Design integration,

plumbing/wiring,

power management

Wiring Diagram

Shaft Validation

10/1

3

10/2

7

11/1

0

11/2

4

12/8

12/2

2

1/5

1/19

2/2

2/16

3/2

3/16

3/30

4/13

4/27

5/11

Race

Gateway #4

Tested Car

Test/Collect 2015 Car

Test Fully Assembled Car

Assisting Other Teams With Tasks

Test Clutch Springs on New Car

Test Clutch Weights on New Car

Fabricate Chain Tensioner

Instrument the 2015 Car

Install Sensors and Brackets to car

Install wiring harness

Firewall and Cockpit Fabrication

Design Chain Tensioner

Install the plumbing

Paint Frame

Rolling Chasis with Steering

Seat Fabrication

Go get plumbing parts

Fabricate Rear Axle

Fabricate Cooling system

Fabricate Steering System

Fabricate Sensor Brackets for 2015+ Cars

Fabricate Braking System

Seat Design

FEA Rear Axle

Gateway #3

Fabricate A-arms

Assemble Drivetrain Components

Design Rear Axle

Machine Upright Components

Fabricate Engine Mounts

Design Sensor Brackets

Design Brake System

Purchase Bearings

FEA of Sprockets

Fully Assembled Suspension System Modeled

Analyze Impact Attenuator Data

Establish Methodology to wiring Connectors

Order Temperature Gauge Stuff

Pedal Fabrication

Design Steering system

Body Fabrication

Design Pushrod Location in Solidworks

Differential Finalize design

Order Cooling Parts

Mold Fabrication

Collect all the components for wiring or order them

Fabricate Secondary Shaft

Body Design

Redo wiring harness

Body Research

Fabricate Sprockets

Design Uprights into Solidworks

FEA Engine Mounts

Weld Frame and Fabricate Rear Box

Research Steering systems

FEA of Secondary Shaft

Select Final Rear Box Design

Figure Out Minimum Required Fluids and Tanks

Chassis Dyno Testing

Design Sprockets

Design Secondary Shaft

Design Engine Mounts

Fabricate Rear Box and Frame

Research Rules on fuel tank requirements

Organize the Rear Box

New Wheel Center Fabrication

Determine Engine Mounting Points

Locate Secondary Shaft Supports

Design Cooling System 3D software

Pick a final design Concept for the rear box

Design A-arms in Solidworks

Identify locations for Cooling system components

Test Clutch Springs on Old Car

Test Clutch Weights on Old Car

Gateway #2

Bearing Research

New Wheel Center Selection

Identify ideal engine operating temperature

Determine the surface area required for cooling

Determine heat output of engine

Research Cooling System Designs From other teams

Design Rear Box

Develop Solid works Models of Rear Box Designs

Design Optimal Final Drive Ratio

Develop MATLAB Acceleration Model

New Wheel Center FEA Testing

Temp Wheel Center Fabrication

Research Braking Systems

Generate Rear Box Ideas

Design New Wheel Centers

Analyze Acceleration Data Analysis

Wheel Center Research

Finalize Suspension Force Points

Determine Initial Force Points

Frame Design

Instrument Previous years cars