Formula 1

Group Members:
Quinn Collett
Steve Godlewski
Tobiah Halter
Jeff Swanson
Academic Advisor:
Dr. Chien Wern
June 4, 2003

Introduction
Formula SAE is a competition focused on
the design and fabrication of an
affordable, weekend racecar.
Performance and reliability are
necessary attributes.
As a Senior Project group we chose to
design three major components of the
car.

Project Scope
Design, fabrication and testing of the
three design components:

Hub Assemblies
Drivetrain
Aerodynamics

Decision Process

Product Design Specifications

External Search
Internal Search
Concept Evaluation

Presentation Outline
Rear Hub and Upright Design
Front Hub and Upright Design
Differential Housing and Drivetrain
Design
Aerodynamics Design

Rear Hub and Upright Design

Components

Bearing Housing
Flanges
Connection Points
Angle Bracket
Bearings
Fasteners

Analysis of Hub

Material: 6061-T6 Aluminum

Yield Strength: 40 ksi
Factor of Safety: 3
Design Stress: 13.3 ksi

Results of FEA Analysis:

Max Von Mises Stress: 14.5 ksi
Maximum Displacement: 0.002 in

Analysis of
Upright
Material: 6061-T6 Aluminum
Yield Strength: 40 ksi
Factor of Safety: 3
Design Stress: 13.3 ksi

Results of FEA Analysis

Max stress: 16.3 ksi
Max Deflection: 0.004 in

Verification
PDS Criteria

Weight:

Size/shape:

Install in less than 120 min.

Can be done inside of an hour: press in bearings, 3 bolts per side

Cost (materials, bearings, bolts):

2 hour yearly overhaul

Maintenance free: sealed bearings, locktite on all screws

Installation:

Components will fit within an 13 inch wheel.

It does fit.

Maintenance:

The hub assembly will weigh less than 17 lbs.

Hub=2.5 lb, Upright=4.5 lb, Total = 7 lb

less than $400

Housing: $54.00, Hub: $186.94, Flange: $65.20, Connectors: $50.54,
Angles: $1.34, Fasteners: $8.61, Bearings: $18.80
Total Cost of Materials: $385.43

Dynamic Testing

Has performed properly to this point

Front Hub/Upright
Design Criteria
PDS

30%-40% weight reduction over last years car

Ideal weight of 14 lbs.
Assembly fit within a 13 in. dia. Wheel
Handle loadings in race conditions
Incorporate connecting points for suspension and steering
systems

Component Selection

Suspension Geometry
Steering Positioning
Brake Components
Bearing Selection

Front Hub/Upright
Analysis
Calculations
Track Conditions
Top speeds 60 mph/ Avg. Speed 30 mph

Safety Factors

Front Hub/Upright
Components
Hub assembly
Two piece design for ease of
maintenance
Double row angular contact
bearing ( axial and radial
loads)

Upright
Spindle

Modeled using
Solidworks
Used to ensure fit
Compatibility with other
components
Clearances and interference

Front Hub/Upright
Materials
6061-T6 Aluminum
304 Stainless Steel

Manufacturing

CNC Mill
Lathe
Press

Front Hub/Upright
Verification
Weight
Last years 32 lbs. This year
11.4 lbs.
64% weight reduction
Under Ideal weight of 14
lbs.

Track testing
Handles loads under
acceleration, deceleration,
and cornering

Problems/Improvements

Two Piece Separation

Spacers
Further Advanced
Optimization
Weight reduction
Cost reduction

Drivetrain
Use of Common
Parts
Honda CBR 600 F1
Limited Slip
Differential

Use of Common
Materials
4140 Steel
6061-T6 Aluminum

Rear Differential
Aluminum Housing
Zexel Torsen Limited
Slip Differential

Sealed Bearings
Retain Gear Oil

Check Valve
Roll-Over and Tilt
Protection

Power Transmission
Axle Shafts
4140-3/4 Steel
U-Joints

Drive Shaft
Splined Drive
Chain and Sprocket

Rear Mono-Brake

Drive Train Verification

Performance
Dyno-Testinig
Road Testing

Weight
Target 50 lbs

Manufacturing Time
Target 15 hours

Production Cost
Target $2000

Failures
Drive Axle Welds
Shielded Bearings

Changes?

Acceleration Torsion
Testing

Aerodynamics & Body

Modeled using 3-D software
package, SOLIDWORKS
Forms CNC machined
Allowed for precision forming
and exact fit

Material: 1/8 fiberglass mat w/

fine mat finish
Light weight and durable

Total Weight: 8.5 lbs.

Significantly below PDS target

Body & Aerodynamics

cont

1992 SAE

Estimated drag coefficient (CD), front lift coefficient (CL), drag force (D) and lift force (L)
CD = 0.14
D = 1.950 lbf
CL = 0.15
L = 0.910 lbf

Body & Aerodynamics

cont

Source: Race
Car Engineering,
Katz

Estimated skin drag coefficient (CF) and surface shear force per unit
surface area () (friction resistance)
CF = 4000
= 901.87 lbf/ft2

Body & Aerodynamics

cont
Overall Performance Evaluation
Overall weight of car significantly minimized
PDS projected weight = 30 lb
Actual weight = 8.5 lb
Dimensions of car w/in 2% of desired
Drag force minimized as specified in PDS
Typical F-1 CD = 1.07
PSU Formula CD = 0.015
Lift force acceptable but could be further minimized by introducing further
down force components which were sacrificed to make room for critical
components (i.e. intake apparatus, radiator)
Typical F-1 CL = -0.99
PSU Formula CL = 0.015
Cooling performance maximized by channeling air over water-cooled
components
average engine temperature w/o channeled air over radiator = 220 F
average engine temperature w/ channeled air over radiator = 200F

Performance in Action