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Formula SAE - PowerPoint


									Formula SAE


Team Members

  Andrew Tyler
 Shawn Albertson
Paul Vandevender
  Adam Pompa
   Matt Davied
 Jake Speilbusch
PSU Racing is embarking on its inaugural
FSAE competition. Our team of six
members was formed August 2006 and
has been diligently working to meet the
goals set forth by the FSAE Rules
committee to compete in the west
competition June 2007.
The objective for the 2007 PSU racing
team is to complete the build of the vehicle
and finish all dynamic events at the west
competition as well as laying a foundation
to ensure success and continual
improvement by the team at future events.
• Our vehicle design utilizes commercially
  available products except for the frame,
  uprights, fuel tank and drivers control
  components. This ensures replacement
  parts availability if needed, as well as
  properly engineered parts for the
• Designing our vehicle to use commercially
  available products minimizes design risk
  by utilizing proven designs to meet the
  criteria of the event. Our fuel injection
  system, E.C.U. and drive-train were all
  assembled from commercially available
  components designed to meet our
         Cost Efffectiveness
• As stated above, we are a first year team
  and have an initial budget of $15,000. We
  have chosen designs that meet the criteria
  set forth by the rules committee and
  satisfy our goal of producing a low-cost
  vehicle. This approach will also help us to
  meet the goal of building a vehicle under
      Conceptual Designs
The first conceptual design utilized side
pods housing two radiators and electronic
equipment. The second conceptual
design utilized a single rear mounted
radiator with no side pods. After carefully
analyzing cost and manufacturing time
projections, the second conceptual design
was chosen to be produced.
     Two Basic Body Designs
• Side Louver Design
  – Consists of bullet type car but with side
  – Space for radiator and electronics.
  – Added Weight

     Two Basic Body Designs
• Bullet design
  – Consists of a straight through body with no
    wings or side louvers.
  – Streamline design.

• The vehicle utilizes a tubular space frame that is composed of T.I.G.
  (Tungsten Inert Gas) welded 4130 chrome-moly steel tubing.
• The cockpit was designed to give the driver room for entering and
  exiting the car, as well as provide room for steering and shifting
  motion of various sized drivers.
• The front portion of the frame provides ample room for drivers with
  different leg lengths.
• The rear portion of the frame was designed using the engine as a
  rigid component.
• A-arm and suspension mounting points of the frame were analyzed
  using Pro-Mechanica and designed to have a safety factor of 3.
• Throughout the frame, the members have been triangulated to
  increase rigidity and reliability.
             Impact Attenuator
• The guidelines set forth by the SAE were met by utilizing
  proprietary soy-based foam from Pittsburg State
  University’s organic polymer research center.
• The foam, through finite element analysis as well as
  destructive testing, showed an average deceleration of
  9.17g. Substantially lower than the 20g maximum.
• The foam was chosen because of superior performance
  to other materials as well as cost. The foam material
  used in the attenuator was purchased for $3.24, a cost
  that is well below other material with similar properties.
             Upright Assembly
• Both the front and rear uprights are green sand castings
  of 356 aluminum alloy with a T6 heat treatment.
• The uprights were analyzed using Pro-Mechanica and
  designed to have a safety factor of 3.
• Using pre-manufactured hubs and bearings from
  commercially available vehicles allows the owner to
  purchase replacement parts from various suppliers.
• Each upright assembly includes the same hub and
  bearings, this simplifies the manufacturing process.
• The suspension utilizes double a-arms in both the front
  and rear.
• The a-arms are comprised of ¾” 4130 chrome-moly steel
  alloy round tubing. The material allows our safety factor
  of 3 to be met.
• A single vertical coil-over shock with push rod activation
  is used on each corner of the vehicle for the dampening
• The a-arms attach to the uprights and frame using 3/8”
  I.D. heim joints. The heim joints are installed in double
  shear to ensure a safety factor of 3.
    Engine and Transmission

• 600 cc Honda Sport Bike Engine
  – Fuel Injected

• 6 speed Honda Transmission
  – Linked to mechanical ratchet shifter
         Engine Control Unit
• An engine control unit (ecu) manufactured by
  Dynojet research is used to control the fuel
  injection system.
• This system uses the stock ecu in conjunction
  with the unit from Dynojet.
• This allows use of the factory spark curve and
  only change the fuel map which is most effected
  by the restricted intake.
• The unit costs substantially less than a stand
  alone ecu.
            Restrictive Intake
• An intake was manufactured using widely
  available polyvinylchloride (pvc) piping.

• The 20mm restrictor was manufactured out of
  aluminum billet.

• The intake system uses 2” pvc to connect the
  restrictor to the factory air box which contains
  one set of the factory injectors.
• A Torsen differential was selected and modified to
  accept a 38 tooth 525 sprocket input.
• This unit will provide traction to each rear wheel
  proportionally, but allow one side to free wheel during
  turns to prevent wheel hop.
• Power is transmitted from the differential via splined
  constant velocity shafts which are then splined to
  commonly available wheel hubs.
• The constant velocity shafts used are from a
  commercially available vehicle and cost effective to
  purchase rather than manufacture.
• Drivers comfort was a major concern during design.
• This matter was addressed by utilizing a movable pedal
  assembly to ensure drivability by drivers with crotch
  height of anywhere from 30” to 36”. This range was
  chosen to accommodate male drivers who fall between
  the 5th and 95th percentile according to the Design
  Criteria for Military Systems, Equipment and Facilities.
  This range also accommodates female drivers within the
  50th-99th percentile.
• Static Events

  – Cost and Manufacturing Analysis

  – Presentation

  – Design
• Dynamic Events

  – Acceleration
  – Skid Pad
  – Autocross
  – Fuel Economy
  – Endurance
     Customer Requirements
• Minimum 60 inch wheel base
• Must have 4 wheels that are not in a
  straight line.
• Wheels must be a least 8 inches in
• Must have dry (slick) and wet (treaded)
  tires to compete.

     Customer Requirements
• Steering must affect at least two wheels.
• Brakes must act on all four wheels from a
  single control.
• Must be equipped with 5 point safety
• Engine is restricted to 610cc or less.
• Air intake restricted to 20 mm.


• Static loading using Pro-Mechanica
• Loads-
  – 650 lbs
     • Car and Driver
  – 2 G’s Lateral
  – 2 G’s Braking
  – 3 G’s Vertical


Ex. Working Drawing

                                           Routing Sheet
COMPANY NAME:            PSU Racing                         Part Name:     Rear Passenger Hub

    Date:   11/17/2006                                      Size of Run: 1 Unit

Oper. #                  Description           OperationMaterial           Time     Feed/ Speeds
    5                    Rapid Prototype         RPT            Poly         24hr          NA
                         Create RPT part

   10                    Create Flask           Ram         Green Sand       .5hr          NA
                         Ram part in green sand
                         Add gating system
                         Remove patterns
                         Place on pouring line

   15                    Pour Part              Casting     356 Al Alloy      2hr          NA
                         Pour 356 Al Alloy
                         in flask
                         Allow to cool
                         Break out part

   20                    Solution Treatment    Heat treat   356 Al Alloy     24hr          NA
                         Heat treat part in
                         Age part in furnace

   25                    Machine Holes            Mill      356 Al Alloy      1hr           ?
                         Machine bearing
                         Machine ball joint
                         clearance                                                              MD/AT
Final Assembly

• In conclusion, our vehicle design is simple yet effective.
  Through F.E.A, destructive testing, and research it is
  determined this design meets or exceeds all criteria set
  forth by the S.A.E. and PSU Racing. The goals of
  manufacturing a product that is easy to manufacture,
  reliable, and cost effective were met. By meeting the
  goals set forth, a vehicle that is marketable to the
  average weekend racer was produced. We appreciate
  the time taken by the advisory committee to review this

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