ODU Formula SAE MAE 435 Midterm Report. The Formula SAE competition challenges teams of university...

ODU Formula SAEODU Formula SAE

MAE 435 Midterm ReportMAE 435 Midterm Report

The Formula SAE competition

challenges teams of university

undergraduate and graduate students

to conceive, design, fabricate,

develop and compete with small, formula style, vehicles.

Formula SAEFormula SAE

Static Event Points:◦ Presentation (75)◦ Engineering Design (150)◦ Cost Analysis (100)

CompetitionCompetition Dynamic Event Points:

◦ Acceleration (75)◦ Skid-Pad (50)◦ Autocross (150)◦ Efficiency (100)◦ Endurance (300)

MATTHEW SANTJER BJORN MALMFELDT CHRIS SAVEDGE MICHAEL TERLESKY ROBERT SLADE RICHARD JONAS GEORGE KOUTROS JASON LENHARDT JOHN PRESGRAVES DANIEL SMITH RYAN TETER NICHOLAS GARNER

Our TeamOur Team

5

SuspensionSuspension Suspension has been

designed in SolidWorks.

Suspension Geometry was identified using

Optimum Kinematics.

SuspensionSuspension Shocks, pushrods,

and rockers have been installed

Camber, caster, and toe has been properly

set

The rockers were designed for ideal motion ratio and linear spring rate

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Differential Analysis Differential Analysis

The differential has been designed and

fabricated.

SolidWorks analysis will be conducted on the existing design.

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IntakeIntake

The intake has been fabricated and

installed.

Currently we are analyzing different

restrictors designs in SolidWorks

The team will 3D print several

restrictors and test on the flow bench.

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ExhaustExhaust

The headers has been installed on the engine and leak

tested.

The firewall is being designed to insure

the seat and fuel tank are not subject to heat produced by exhaust system.

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AerodynamicsAerodynamics

Body panels are being fabricated using fiberglass.

Analysis will be conducted with Fluent software to calculate maximum downforce generated by diffuser.

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BrakesBrakes

The calipers have been mounted to the uprights.

The pedals have been

fabricated & installed and master cylinders

mounted on the frame.

Hydraulic pressure has been adjusted and a

thermal analysis is being conducted on the

system.

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Control SystemControl System The manual shifting

lever has been fabricated and

installed on the car. Force analysis for

the pneumatic shifting system has

been conducted.

MXL Strada is awaiting purchase

and will be electrically mated with ECU upon

arrival.

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Pedal AssemblyPedal Assembly The pedal setup is a three pedal assembly

with a clutch, brake, gas arrangement.

Analysis has been conducted on each pedal

using SolidWorks

• The chassis design and fabrication has been

completed.

• Our team started by fabricated the current table to be level in all planes and mounting holding brackets

for the front, console, driver, and rear hoops.

• The structural members have been fabricated using hollow 4130 steel using the

following types:

• 1”x1”x0.049” Square• 1”x0.095” Round• 1”x0.065” Round• 1”x0.049” Round

Progress - Chassis Design Progress - Chassis Design

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Progress - Parts Progress - Parts

Metal Concepts Inc. has fabricated parts for the

pedals, differential, intake, and suspension.

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Progress - SteeringProgress - Steering

The steering rack has been aligned in plane

with uprights for smooth wheel movement.

The steering rods have been fabricated and

connected to the steering knuckles on the

uprights.

The steering wheel has been located and mounted for best

possible driver ergonomics.

Progress - UprightsProgress - Uprights

The uprights have been designed, fabricated and

installed. The upper and lower A-Arms and

steering have been connected and tested.

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Questions?Questions?