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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