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Sheffield Hallam University
Formula Student
Virtual Lecture by
R Harris MSc, BEng, CEng, MIET
Lecture Objectives• To understand the design of vehicle to
meet a particular specification; Formula Student
• To examine the design process
• To understand the engineering decisions made
• To review the final product
What is Formula Student ?
" While ostensibly about the design and production of a single-seater racing car, Formula Student is actually more about building future engineering talent, not just in design and manufacture, but in many of the management, marketing and people skills so vital in the modern world, across all sectors of employment. "
Institution of Mechanical Engineerswww.imeche.org
How does it relate to Formula SAE* ?
• A British version of Formula SAE using the same rules.
• There are also similar events in Italy, Brazil, Australia.
*Society of Automotive Engineers
Basic Rules• The design must conform to the 119 page SAE rule
book• A completely new car must be built every two years• "Vehicles entered into Formula SAE competitions
must be conceived, designed, fabricated and maintained by the student team members without direct involvement from professional engineers, automotive engineers, racers, machinists or related professionals."
Basic Design
• Open cockpit• Must have 4 wheels• Brakes must operate on all 4 wheels• Max 610cc engine• Super or turbo charging permitted• Must have roll hoops for driver safety• Monocoque and space frame acceptable• Seat harness mandatory
Typical Designs
The next slides give examples of vehicles that have previously been constructed
India – Delhi College of Engineering,
Canada – University of Toronto
Sheffield Hallam’s Formula Student car
Key Design Decisions Needed• type of engine – petrol, diesel, no of
cylinders, turbo or supercharged, engine management
• drive train – shaft drive, chain drive, transmission type
• frame – monocoque or space frame
• frame material(s)
Design Constraints• physical resources - machine shops,
welding facilities, modelling software etc
• intellectual resources – student and staff experience and expertise
• students skill set
• time, people and finance available
• cost
Analysis of Spaceframe Design
Solid Model of Baseline Chassis
Driver Size Relative to Chassis
Does the Rollbar Meet the specificatioin?
Check with a Real Person
Suspension
Constraints:
• need to leave space for driver
• mounting points available on frame
• need to minimise weight of components
• need to used commercially available components
Front Suspension and SteeringAn initial Proposal
Front SuspensionAs implemented
Rear Suspension
Rear Suspension
Complete Chassis
Engine and Transmission
Constraints:
• physical size to fit frame
• capacity allowed
• expertise available
• finance available
• development time available
Decisions Made
• commercially available motorcycle engine
• use liquid cooling as more flexible
• normally aspirated due to limited time and expertise develop forced induction
• use existing engine management system initially
• optimise on dynamometer
• use existing gearbox
Issues to Resolve
• torque/speed characteristics need modifying to achieve low speed torque
• need additional cooling to cope with low air velocity
• gear selection
Dynamometer Engine Testing
Engine in Frame
Front Suspension and Steering
SHU Racing Team
• SHU Racing team students who work on the car have individual projects
• Matthew Ross is a current student
• He has kindly provided his presentation to show his project of improving the petrol tank for the car
MY PROFILE
MATTHEW ROSS
• 19 YEARS OLD• FROM LINCOLNSHIRE
• FIRST YEAR STUDENT AT SHEFFIELD HALLAM
• STUDYING COMPUTER AIDED DESIGN TECH
FUEL PUMPSUZUKI GSX MOTORBIKE
• FUEL FILTER• FUEL PRESSURE
REGULATOR• FUEL PUMP
UNIT MUST BE SUBMERGED
MUST REMAIN VERTICAL DURING OPERATION
PROBLEMS WITH OLD TANK
• DESIGNED FOR USE WITH PREVIOUS CAR
• PUMP COULD NOT BE SUBMERGED INSIDE TANK
• TANK WAS LOCATED NEAR EXHAUST MANIFOLD
• FUEL FILLER NECK WAS ILLEGAL (FIA / SAE RULES)
MUST ACCOMMODATE FUEL PUMP
MUST FIT INTO CHASSIS CAVITY
MUST HAVE SUFFICIENT CAPACITY
FILLER NECK MUST COMPLY WITH REGULATIONS
INTERNAL VOLUME CAN BE CALCULATED
MANUFACTURING PLANS CAN BE CREATED
INTERFERENCE FITS CAN BE IDENTIFIED
MUST ACCOMMODATE FUEL PUMP
MUST FIT INTO CHASSIS CAVITY
MUST HAVE SUFFICIENT CAPACITY
FILLER NECK MUST COMPLY WITH REGULATIONS
INTERNAL VOLUME CAN BE CALCULATED
MANUFACTURING PLANS CAN BE CREATED
INTERFERENCE FITS CAN BE IDENTIFIED
MIG WELDS ON NEW PETROL TANK
NEW PETROL TANK OFFERS:
20% WEIGHT REDUCTION
INCREASED CAPACITY FROM 4 TO 5 LITRES
Initial Design for the Electrical System
Circuit diagram
Body Work - Design Options
Bodywork designs and ideas
CAD drawings of body on frame
Profile Image of Car
Actual bodywork
Track testing
Initial Testing
At the Event
Each team car goes though rigorous testing process
• Static Events:Design, Cost & Presentation Judging - High scoring part of competitionTechnical & Safety ScrutineeringTilt TestBrake & Noise Test
• Dynamic EventsSkid Pan (Figure of 8)SprintAccelerationEndurance & Fuel Economy
Engine testing
Scruitneering
The Noise Test
Tilt test
The brake test
Practice
The BIG event!• Average speed should be 48 km/hr (29.8 mph)
to 57 km/hr (35.4 mph) with top speeds of approximately 105 km/hr (65.2 mph).
• The event will be run as a single heat approximately 22 km (13.66 miles) long. Teams are not allowed to work on their vehicles during the heat.
• A driver change must be made during a 3minute period at the mid point of the heat.
Starting grid
Video of the Race
The finishing line
On the podium
The team