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:
 The hub assembly will weigh less than 17 lbs.
 Hub=2.5 lb, Upright=4.5 lb, Total = 7 lb
 Size/shape:
 Components will fit within an 13 inch wheel.
 It does fit.
 Maintenance:
 2 hour yearly overhaul
 Maintenance free: sealed bearings, locktite on all screws
 Installation:
 Install in less than 120 min.
 Can be done inside of an hour: press in bearings, 3 bolts per side
 Cost (materials, bearings, bolts):
 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  Failures
 Dyno-Testinig  Drive Axle Welds
 Road Testing  Shielded Bearings

 Weight  Changes?
 Target 50 lbs

 Manufacturing Time
 Target 15 hours

 Production Cost
 Target $2000
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 con’t…
Lift and Drag Coefficients
(as effected by ground promimity)

0.35
0.3
Coefficient

0.25
0.2 Drag Coefficient
0.15 Lift Coefficient
0.1
0.05
0
0 0.05 0.1 0.15
h/L
© 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 con’t…

Source: Race Car

Engineering, Katz

 Estimated skin drag coefficient (CF) and surface shear force per unit
surface area (τ) (friction resistance)
 CF = 4000 τ = 901.87 lbf/ft2
Body & Aerodynamics con’t…
 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 = 200°F
Performance in Action