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P09221: Innovative Composite Parts for a Formula SAE Racecar

Explore innovative composite parts designed by the team members to meet primary engineering specifications for the chassis, undertray, and pedal box of a Formula SAE racecar.

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P09221: Innovative Composite Parts for a Formula SAE Racecar

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  1. P09221: Innovative Composite Parts for a Formula SAE Racecar Team Members: David Holland Theodore Kusnierz Anthony Salvo Ryan Baldi Charles Thomas Martin Iwanowicz

  2. Primary Engineering Specifications Chassis 1.) Resistant to cone impact @ 75mph 2.) Bump, accel, brake, corner loads: 3g/1.5g/1.5g 3.) Torsional Stiffness: 2500lb*ft/degree 4.) Weight < 55lbs Undertray 1.) Minimum clearance between chassis/suspension and tray: 1/32” 2.) Lift: -30+lb @ 25mph 3.) Weight: < 25lb Pedal Box 1.) Pedal load = 200lb 2.) Weight: < 1.5lb 3.) Deflection Magnitude: < .010” 4.) Accommodate driver heights between 5’5” and 6’5”

  3. Functional Decomposition

  4. Concepts Generated • Roll Hoop Attachment: • Bolted • Bolted and Bonded • Co-cured and bolted • Cut out/contour flange • Solid planar flange & move fuel cell Chassis • Chassis Shape: • Curved panels • Flat, planar facet • Facets with slight curvature/twist

  5. Concepts Generated Chassis Manufacturing Wood/MDF/Fiber Glass/Tooling Board Plug Metal Template Plug (Photo: Harbor Patterns F-22 Canopy) Graphite Pre-Preg Mold (Photo: Harbor Patterns Bell Helicopter Skin Mold) Gel-Coat/Fiberglass Mold

  6. Concepts Generated Pedal Box • Stiffening Scheme: • Flat plate w/ core under pedal box • Rectangular bonded inserts • Ribs bonded in channels • Manufacturing Concepts: • Plastic/metal plate with milled channels • Solid carbon with channels milled in it • Pultrusion • Vacuum Bagging • Infusion • Compression Molding

  7. Concepts Generated Undertray: • Tunnel Shape: • Large Radii – Ease of Manufacturing • Sharp Corners – Better flow properties • Extend Past Rear Wheels – Better flow properties • Shorter than Rear Wheel Centerline – Legal, Lighter, Easier to manufacture • Stiffening: • Stiffeners in flow • Add no stiffeners • Stiffen above tray

  8. Concepts Generated Undertray: • Jacking Point Concepts: • Carbon: Integrated into tray, jack up car w/ tray • Aluminum: Bonded onto tray, jack up car w/ tray • Steel: Cut out undertray, weld steel to chassis, do not jack up car w/ tray • Jacking Point Regulations: • Must be painted orange • Higher than 3” off ground but below 6.9” • Visible from 3 feet away • Bottom half of tube must be exposed • Material: steel or aluminum

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