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2005 FSAE Rolling Chassis

2005 FSAE Rolling Chassis. Todd Anderson Matthew Blackwood David Hovater Josh Smith Jessica Yoho. Project Statement. Design, build, and test a rolling chassis for integration with the 2005 UA Formula SAE car design. Design Constraints.

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2005 FSAE Rolling Chassis

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  1. 2005 FSAE Rolling Chassis Todd Anderson Matthew Blackwood David Hovater Josh Smith Jessica Yoho

  2. Project Statement Design, build, and test a rolling chassis for integration with the 2005 UA Formula SAE car design.

  3. Design Constraints • Environmental: Most of the components on the 2005 vehicle are reusable • and/or can be recycled. • Sustainability: The chassis components have been designed and • manufactured to endure the entire length of the competition. • Manufacturability: All fabricated parts can easily be reproduced by a full • service machine shop and all other components can be • purchased from almost any motor vehicle parts supplier. • Social: The project was completed in conjunction with student members of • SAE and supporting faculty. • Economical: The cost of the project was minimized by buying only necessary • parts and manufacturing the remaining parts. • Health & Safety: All FSAE safety requirements were implemented into the • design to ensure driver safety.

  4. Project Timetable 11/3/04

  5. Overall Budget Purchased Items $6886.00

  6. Objectives • Reduce Weight • Reduce Complexity • Less Tabs • Design Integration • Increase Driver Comfort • Increase Driver Diversity • Increase Strength • Increase Dimensional Accuracy

  7. 2005 Rolling Chassis • 66 inch Wheelbase • 48/46 inch Front/Rear Track • 106 inch Overall length • Weighs Approximately 120 lbf

  8. Steering: Overview • Ackerman Geometry • Adjustable Toe-Angle • 12 Foot Turning Radius

  9. Steering Rack Jr. Dragster Rack-N-Pinion Chassis Shop • Track Travel: 3” • Weighs 1.96 lbs • Rack Length is 8.5” • 1.125 Turns Lock to Lock

  10. Seat: Overview • Carbon Kevlar Fabric • Foam Mold • High Lateral Support • Lightweight • Increased Strength

  11. Seat: Mold Process Phase I Phase II Phase III Phase IV

  12. Suspension: Overview • Pull Rod Setup Front • Push Rod Setup Rear • Low Roll Center • Double A-arm

  13. Suspension: Characteristics Roll Gradient – Chassis Roll Under Lateral Accel • 1.5 deg / g • 2.3 degrees of roll at 1.5 g lateral acceleration

  14. Suspension: Front Geometry • Unparallel, Unequal Length Control Arms Front Top

  15. Suspension: Front Layout Roll Bar Fox DHX Shock Rocker Pull rod

  16. Suspension: Front Rates • Wheel rates and roll bar adjustable • Front Wheel rates • 96 lbs/in • 125 lbs/in • 155 lbs/in • Roll Gradient • 1.35 deg/g • 1.50 deg/g • 1.65 deg/g Adjustable Shock Mount in Rocker

  17. Suspension: Rear Geometry • Unparallel, Unequal Length Control Arms Front Top -6 -4 -2 0 2 4 6

  18. Suspension: Rear Layout DHX Shock Rocker Push rod

  19. Suspension: Rear Rates • Wheel rates also adjustable • Rear Wheel Rates • 86.1 lbs/in • 105.0 lbs/in • 125.0 lbs/in Adjustable Pushrod Positions

  20. Brakes: Overview • 3 Disc Setup • 2 Outboard Brakes in Front • 1 Inboard in Rear • 9” Diameter Rotors • Dual Piston Calipers • Left Foot Brake setup (Only two Pedals) • Balancing Bar

  21. Brakes: Calipers & Rotors • Wilwood PS-1 Calipers • Dual 1.12 inch pistons • 9 inch Custom Rotors Front • 220 mm Suzuki GSXR 600 Rear Rotor • Dual master cylinders • Balancing Bar used to Adjust Bias PS-1 Caliper Dual MC Balance bar

  22. Rear Uprights: Overview • 3104 Aluminum • Taylor Racing Engineering Stub Axle, Hub, and Bearing • Designed for Spherical Bearings A-arm Attachment Points • Assembly Weight: 6.25 lbs

  23. Rear Uprights: Analysis • ANSYS Analysis • Constraints / Loading Conditions • Maximum Deflection is 0.002” • Maximum Stress is 3500 psi

  24. Rear Upright: Production • CNC Milling Machining • 25 hrs Machine Time • Complete by Tuesday, December 14

  25. Stub Axle: Assembly • Stub Axle Assembly used in 2004 Car • 4130 Chrome-Moly Steel • More Proven, and Lighter than Previous Design • Manufactured by Taylor Racing

  26. Rear Frame: Overview • Semi-Stressed Engine • Square Tubing for Rear Suspension • Removable Roll Hoop Bracing for Engine Accessibility • 4130 Chrome-Moly Steel Spaceframe • Approximate Weight is 15 lbs

  27. Rear View: Analysis • Modeled Engine as Frame Members • Braking Analysis • 910 lbf Applied at Wheel • Cornering Analysis • 540 lbf Applied at Wheel

  28. Front Frame: Overview • 4130 Chrome-Moly Space Frame • Made of 48 Members • Approx 60 in Long • 36 lbf

  29. Front Frame: Tubing Sizing • 1 x 0.095 Round • Front Roll Hoop • Main Roll Hoop • 1 x 0.065 Round • Roll Hoop Bracing • Side Impact Members • Front Bulkhead • 1 x 0.035 Square • Base of Frame • Upper A-arm Mount 1 x 0.095 ROUND 1 x 0.065 ROUND 1 x 0.035 ROUND 1 x 0.035 SQUARE

  30. Front Frame: System Integration

  31. Front Frame: ANSYS Analysis • Fully Meshed Front Frame • BEAM4 Element used for Square Tubing • PIPE16 Element Used for Round Tubing • Simulations • Braking Forces • Cornering Forces • Constrained at Main Roll Hoop

  32. Load Values: 910 lbf 360 lbf Front Frame: Braking Simulation Results: Max Deflection: <0.080 inches Max Stress: <32 ksi

  33. Load Values: 625 lbf 150 lbf 360 lbf 525 lbf 60 lbf Front Frame: Cornering Simulation Results: Max Deflection: <0.045 inches Max Stress: <12 ksi

  34. Front Frame: Other Features • 12 inches Wide at Driver’s Feet • Accommodates Drivers up to Approx. 6’ 2” • Increased width at Main Roll Hoop to Increase Stiffness and Space for Subsystems to Mount • Driver’s Feet Elevated 4” to Increase Support and Comfort • Driver Sits Underneath the Roll Bar

  35. Front Uprights: Overview • Welded Construction • Steel Construction • 16 Gage Mild steel • Cold Drawn Steel • Weight: 2.75 lbf • Aluminum Hub • Tapered Roller Bearings

  36. B Front Uprights: Assembly A Upright/Spindle B Spherical Bearing Housing C Rear Seal D Timken Roller Bearing E Hub F Timken Roller Bearing A C D E F

  37. Front Uprights: ANSYS Analysis • Element Type: SOLID185 • Constrained: • All Directions at Top Mounting Point • Longitudinal and Laterally at Bottom Mounting Point • Simulations • Braking • Cornering

  38. Front Upright: Simulations Cornering Results Max Deflection: <0.004 in Max Stress: <16 ksi Braking Results Max Deflection: < 0.005 in Max Stress: < 6 ksi

  39. Front Uprights: Hub • Forged Aluminum Construction • Weighs 1.9 lbf • 4 x 100mm Bolt Pattern • Both Wheel and Brake Rotor • Bolts for Brake Rotor • Press in Studs for Wheel

  40. Front Upright: Other Features • Brake Caliper Bracket Integrated into Steering Mount • Compact Box Design • Plasma Cut Parts • 7/8 inch Nylon Lock Nut • Precisely Welded

  41. Frame: Overall Construction Frame members cut to length Frame joints milled Some frame members were shaped to fit properly using grinding wheel or hand file Pieces located on frame using jigs fabricated by team members Once frame members were located properly they were welded in place using TIG or MIG welder.

  42. Frame Construction Cont… • Front frame fabrication began with the placement and welding of the lower frame rails • Once lower frame rails were welded, the upper frame rails and connecting members were located properly in relation to the lower frame rails and welded in place

  43. Frame: Roll Hoop Fabrication • Front and main roll hoops were constructed of 0.095 in wall thickness 4130 Chrome-Moly steel as per FSAE rules • Bending the front and main roll hoops was accomplished with a mandrel bender

  44. Frame: Rear Frame Construction • Since a semi stressed engine is a major part of the vehicle design, it was necessary to use the engine as a guide during construction • The engine was placed on a steel table, and each rear frame member was located properly in relation to the points where the frame mounts to the engine block • Once the rear frame members were properly placed, they were welded in place

  45. Special Thanks: Construction • Arnar Thors • Garrett Davis • Matt Moody • Wren Keith • Andrew Truitt • Stephen Snoddy • Jeremy Hunter • Ashley Erickson • Charlie Aleman • Sadie Cole • Josh Newton • John Lewis • James Largin

  46. Special Thanks: Support • Ken Dunn • Ms. Hamric • Ms. Bedingfield • Scott Prescott • Barry Johnson • President Witt • Dean McDowell • Dr. Woods • Dr. Todd • Dr. Sutton • Dr. Parker • Mr. Newman • Sam Tingle • Joe Howell • Jim Edmunds

  47. Special Thanks: Companies • Timken • Cain Steel • Fox Racing • Aurora • Hesco • Weld Racing • WISE Alloys

  48. Special Thanks: Sponsors • Financial Affairs Committee • Dr. Sutton • Mercedes • UA ASME

  49. Questions

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