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2012-2013 SAE Formula Car 1 st Midterm Update

2012-2013 SAE Formula Car 1 st Midterm Update . Management . Miles Martschink. The Goal. To Evolve Last Years Car Lighter, Faster and More Reliable Quality Engineering. Structure, Organization and Efficiency. Large groups with sub groups Higher Quality Efficient Structure.

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2012-2013 SAE Formula Car 1 st Midterm Update

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  1. 2012-2013 SAE Formula Car1st Midterm Update

  2. Management Miles Martschink

  3. The Goal • To Evolve Last Years Car • Lighter, Faster and More Reliable • Quality Engineering

  4. Structure, Organization and Efficiency • Large groups with sub groups • Higher Quality • Efficient Structure

  5. Management Team • Myself and Three Marketing Students and a Graphic Design Major • Strong Division of Labor • Looking to include more departments

  6. Where We Are

  7. Suspension Travis Wall

  8. Control arms • Control arms • 18” lower A arms • 16.41” upper A arm • Fully adjustable

  9. Shocks • Will mount from the lower A arm to a rocker and then return to the lower A arm

  10. Wheels and Tires • Keizer Wheels • 6.5 lbs • 5 lug design • 6” backspacing • 8” wide • Hoosier racing tires • 43169 • 20.0 x 7.5-13 dimensions, 20.6“tall, 8.0“ tread, 9.4“wide, 7.0-9.0“wheel, R25B compound, $176.80

  11. Uprights • Finalizing front upright design • Machined out of billet aluminum • Determine the rotor, caliper and master cylinder size • Stress analysis for components

  12. Controls Jeff Manning

  13. Controls • Pedal Assembly Design • Created AutoCAD draft of the throttle and clutch pedal • Final design with dimensions in Solid Works • Key Feature • Hanging pedals that are adjustable to the driver • Better feel than floor mounted pedals • Improve scoring in the dynamic portion of the Formula SAE competition

  14. Shifting • Preliminary research of electronic shifting is underway • Ideas • Controlled with 2 Buttons • Rack N Pinion Choice • Removing 1st Gear • Activated Switches Controls 6 5 4 3 2 N 1

  15. Controls Steering • Full Parts List Created • Re-using Steering Wheel • Rack and Pinion • 6.4:1 Ratio • Steering Column • Chromoly • Two U-Joints and 1 Heim Joint

  16. Intake Mark Griffin

  17. Intake • Basic Parts of the Intake Manifold 1. Ram Pipe 2. Plenum 3. Runners

  18. IM Basics • Torque in the high rpm range • Acoustic behavior • Incident and reflective waves

  19. IM Basics Continued: -Piston intake stroke - BDC/TDC

  20. IM Basics Continued -Plenum Chamber -Resonance Chamber -Surge Volume -Mass Spring System

  21. Cooling Janet Bivens

  22. Radiator Type Single Cross Pass Flow HX Electric fan Mechanical pump Loads Engine Lube Oil Cooler Calculations Q = ṁcp(Tin-Tout) Q = U A F ΔT(log mean) F= factor based on air and water temperatures and type of heat exchanger Assumptions: Water Th = 104C Tc= 88C ṁ = 0.1667kg/s – 1.89kg/s Air Th = 49C Tc = 27C U = 400W/m^2K – 850W/m^2K (for water side) Cooling Systems Lo Cooler Water pump

  23. Cooling Systems • Results • Q = 11.64KW • A = 22200cm^2 – 10400cm^2 • Set backs and future goals • Find way to determine heat transfer surface area of commercially available radiators. • Price comparison: commercial / custom. • Engine testing to obtain actual data and recalculate Q and A. • Create computer program to perform calculations. • Once radiator is installed, determine Q removal effectiveness.

  24. Exhaust Kyle Brady

  25. Exhaust • Material selection complete • Calculated engine speed used for decibeltesting • RPM= • Will test engine noise at 11,000 rpm Example of exhaust headers

  26. Exhaust Parts and Materials • 1010 Mild Steel for Runners • 0.049 Wall Thickness • Thermal Exhaust Wrap • Lowers Radiant Heat • Keeps Exhaust Hot • Muffler • Yoshimura TRC Slip-On Top: Exhaust headers wrapped in thermal wrappings Bottom: Yoshimura TRC Exhaust

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