Professional Documents
Culture Documents
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
Presentation Outline
Rear Hub and Upright Design
Front Hub and Upright Design
Differential Housing and Drivetrain
Design
Aerodynamics Design
Components
Bearing Housing
Flanges
Connection Points
Angle Bracket
Bearings
Fasteners
Analysis of Hub
Analysis of
Upright
Material: 6061-T6 Aluminum
Yield Strength: 40 ksi
Factor of Safety: 3
Design Stress: 13.3 ksi
Verification
PDS Criteria
Weight:
Size/shape:
Installation:
Maintenance:
Dynamic Testing
Front Hub/Upright
Design Criteria
PDS
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
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
Weight
Target 50 lbs
Manufacturing Time
Target 15 hours
Production Cost
Target $2000
Failures
Drive Axle Welds
Shielded Bearings
Changes?
Acceleration Torsion
Testing
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
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
Performance in Action