Formula1 Final Presentation

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Formula 1: 

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: 

Project Scope Design, fabrication and testing of the three design components: Hub Assemblies Drivetrain Aerodynamics

Decision Process: 

Decision Process Product Design Specifications External Search Internal Search Concept Evaluation

Presentation Outline: 

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

Rear Hub and Upright Design: 

Rear Hub and Upright Design


Components Bearing Housing Flanges Connection Points Angle Bracket Bearings Fasteners

Analysis of Hub: 

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: 

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: 

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: 

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

Front Hub/Upright: 

Front Hub/Upright

Front Hub/Upright: 

Front Hub/Upright Materials 6061-T6 Aluminum 304 Stainless Steel Manufacturing CNC Mill Lathe Press

Front Hub/Upright: 

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: 

Rear Differential Aluminum Housing Zexel Torsen Limited Slip Differential Sealed Bearings Retain Gear Oil Check Valve Roll-Over and Tilt Protection

Power Transmission : 

Power Transmission Axle Shafts 4140-3/4” Steel U-Joints Drive Shaft Splined Drive Chain and Sprocket Rear Mono-Brake

Drive Train Verification: 

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: 

Acceleration Torsion Testing

Aerodynamics & Body: 

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…: 

Body & Aerodynamics con’t… 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 © 1992 SAE

Body & Aerodynamics con’t…: 

Body & Aerodynamics con’t… Estimated skin drag coefficient (CF) and surface shear force per unit surface area (τ) (friction resistance) CF = 4000 τ = 901.87 lbf/ft2 Source: Race Car Engineering, Katz

Body & Aerodynamics con’t…: 

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: 

Performance in Action

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