Formula 1 Formula 1 Group Members: Group Members: Quinn Collett Quinn Collett Steve Godlewski Steve Godlewski Tobiah Halter Tobiah Halter Jeff Swanson Jeff Swanson Academic Advisor: Academic Advisor: Dr. Chien Wern Dr. Chien Wern June 4, 2003 June 4, 2003
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Formula 1 Group Members: Quinn Collett Steve Godlewski Tobiah Halter Jeff Swanson Academic Advisor: Dr. Chien Wern June 4, 2003.
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Formula SAE is a competition focused on Formula SAE is a competition focused on the design and fabrication of an the design and fabrication of an affordable, weekend racecar. affordable, weekend racecar. Performance and reliability are necessary Performance and reliability are necessary attributes. attributes.
As a Senior Project group we chose to As a Senior Project group we chose to design three major components of the design three major components of the car. car.
Project ScopeProject Scope
Design, fabrication and testing of the Design, fabrication and testing of the three design components:three design components: Hub AssembliesHub Assemblies DrivetrainDrivetrain AerodynamicsAerodynamics
Rear Hub and Upright DesignRear Hub and Upright Design Front Hub and Upright DesignFront Hub and Upright Design Differential Housing and Drivetrain Differential Housing and Drivetrain
Analysis of HubAnalysis of Hub Material: 6061-T6 AluminumMaterial: 6061-T6 Aluminum Yield Strength: 40 ksiYield Strength: 40 ksi Factor of Safety: 3Factor of Safety: 3 Design Stress: 13.3 ksiDesign Stress: 13.3 ksi
Results of FEA Analysis:Results of FEA Analysis: Max Von Mises Stress: 14.5 ksiMax Von Mises Stress: 14.5 ksi Maximum Displacement: 0.002 inMaximum Displacement: 0.002 in
The hub assembly will weigh less than 17 lbs.The hub assembly will weigh less than 17 lbs. Hub=2.5 lb, Upright=4.5 lb, Total = 7 lbHub=2.5 lb, Upright=4.5 lb, Total = 7 lb
Size/shapeSize/shape: : Components will fit within an 13 inch wheel.Components will fit within an 13 inch wheel. It does fit.It does fit.
MaintenanceMaintenance: : 2 hour yearly overhaul2 hour yearly overhaul Maintenance free: sealed bearings, locktite on all screwsMaintenance free: sealed bearings, locktite on all screws
InstallationInstallation: : Install in less than 120 min.Install in less than 120 min. Can be done inside of an hour: press in bearings, 3 bolts per sideCan be done inside of an hour: press in bearings, 3 bolts per side
Cost Cost (materials, bearings, bolts): (materials, bearings, bolts): less than $400less than $400 Housing: $54.00, Hub: $186.94, Flange: $65.20, Connectors: $50.54, Housing: $54.00, Hub: $186.94, Flange: $65.20, Connectors: $50.54,
Angles: $1.34, Fasteners: $8.61, Bearings: $18.80Angles: $1.34, Fasteners: $8.61, Bearings: $18.80 Total Cost of Materials: $385.43Total Cost of Materials: $385.43
Dynamic TestingDynamic Testing Has performed properly to this pointHas performed properly to this point
Front Hub/UprightFront Hub/Upright Design CriteriaDesign Criteria
PDSPDS 30%-40% weight reduction over last years car30%-40% weight reduction over last years car Ideal weight of 14 lbs.Ideal weight of 14 lbs. Assembly fit within a 13 in. dia. WheelAssembly fit within a 13 in. dia. Wheel Handle loadings in race conditionsHandle loadings in race conditions Incorporate connecting points for suspension and steering Incorporate connecting points for suspension and steering
Body & Aerodynamics Body & Aerodynamics con’t…con’t…
Overall Performance EvaluationOverall Performance Evaluation Overall weight of car significantly minimizedOverall weight of car significantly minimized
Dimensions of car w/in 2% of desiredDimensions of car w/in 2% of desired
Drag force minimized as specified in PDSDrag force minimized as specified in PDS Typical F-1 CTypical F-1 CD D = 1.07= 1.07 PSU Formula CPSU Formula CD D = 0.015= 0.015
Lift force acceptable but could be further minimized by introducing further Lift force acceptable but could be further minimized by introducing further down force components which were sacrificed to make room for critical down force components which were sacrificed to make room for critical components (i.e. intake apparatus, radiator)components (i.e. intake apparatus, radiator)
Typical F-1 CTypical F-1 CL L = -0.99= -0.99 PSU Formula CPSU Formula CL L = 0.015= 0.015
Cooling performance maximized by channeling air over water-cooled Cooling performance maximized by channeling air over water-cooled componentscomponents
average engine temperature w/o channeled air over radiator = 220average engine temperature w/o channeled air over radiator = 220°F°F average engine temperature w/ channeled air over radiator = 200°Faverage engine temperature w/ channeled air over radiator = 200°F