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ODU Formula SAE Fall 2012 Final Report

ODU Formula SAE Fall 2012 Final Report . 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. Gantt Chart.

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ODU Formula SAE Fall 2012 Final Report

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  1. ODU Formula SAE Fall 2012 Final Report

  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. Gantt Chart

  6. The Frame • Fully welded together • Weighs approximately 46 lbs • Made entirely out of 1” OD steel tubing

  7. Control Arms Travis Wall

  8. Suspension Overview • Multiple Component • Formula SAE Rules • Min 60” wheel base • Min 8” wheel • Min 1” jounce and min 1” rebound

  9. Control Arms The Control arms are what attach the uprights to the frame of the car. Designing Started September 1st Complete redesign was finished 11-16-12

  10. Control Arms • Front and rear control arms designed in Solidworks Lower Rear Lower Front Upper Front Upper Rear

  11. Suspension-Uprights Cody Merkes

  12. DESIGN • Upright piece for better angles • Caliper mount added • Staggered center

  13. FABRICATION • L&W Machining for uprights • Weld fabrication for upright piece

  14. Rockers & Shocks John Rynders II

  15. Rockers and Shocks • Finalize the suspension design

  16. Rockers :Design Phase • Front Motion Ratio 2.021 • Rear Motion Ratio 1.786

  17. Rockers: Fabrication Steps • Prepared file • Related to fabrication • What steps need to be taken • Briefly describe any special manufacturing processes

  18. Suspension Analysis Aaron Cohen

  19. Suspension Δ Wheel 2” 2” Δ Spring 0.9895” 1.1195” • Motion Ratio: 2.021 / 1.786

  20. Shocks • Shock Dyno results: Compression Rebound

  21. Tires And Wheels Lindsey Draper

  22. Tires and Wheels

  23. Calculations • Lateral Force • Normal Force • Camber Angle • Increase in Normal Force causes an increase in tire wear

  24. Shifting Jeff Manning

  25. Electronic Shifting • Controlled with 2 buttons on the steering wheel (right thumb) • Skipping 1st gear to avoid neutral • Activated switches /LED Display • All allow for higher scoring in the dynamic events 6 5 4 3 2 N 1

  26. Shifting Actuator • Prototyped mechanical aspects of electronic shifting • Designed the actuator mount in SolidWorks.

  27. Shifting Wiring Diagram • Electronics diagram designed by Connor Huffington. • Compiled the order form for the actuator and actuator mount material.

  28. Steering And Pedal Assembly Todd Hayward and Nick Chinyavong

  29. Steering Rack • Rack and pinion has steering ratio of 6.4:1 • Low ratio in order to turn wheels at maximum rotation while barely turning steering wheel

  30. Pedal Assembly • Brake pedal 1.5” thick, throttle/clutch .75” thick • Adjustable foot pads • Pulley attached to throttle/clutch for the cables

  31. Pivot Piece • Slots for all three pedals to rotate • Holes for the two master cylinders • Four holes where the pedals and pivot attach to the mounting piece

  32. Mounting Piece • Adjustable so pedal assembly • Mounts to tab on front of frame and to rack and pinion

  33. Final Assembly

  34. Seat Lindsey Draper

  35. Seat

  36. Driver Saftety Aid Headrest

  37. Intake Manifold Testing Arron Kun mu

  38. Design and Testing

  39. Intake Manifold Production Mark Griffin

  40. Carbon Fiber Fabrication • Production Phase (Currently Underway) • Flange to Runner Transition Piece 3D Print • - Carbon Fiber Setup.

  41. Cast Aluminum Pieces • Foundry Materials • Process • Cope and Drag

  42. Cooling Lateef Shodeinde

  43. Radiator Type Single Cross Pass Flow HX Electric fan Mechanical pump Loads Engine Lube Oil Cooler GSXR 600 Radiator 2 rows of coolant tubes – maximize cooling surface area Opposite side inlet and outlet 11.5”X6” X2” Approximate heat transfer SA of over 10000cm^2 (consistent with desired area of 10400cm^2) Made from lightweight aluminum Cost effective at 114$ Fan: 6” Electric Fan 1500cfm Over flow tank will be a 1L Nalgene water bottle to help minimize weight. Cooling: Design and Fabrication

  44. Fuel Systems Janet Bivens

  45. Fuel: Design and Fabrication • Wedge shaped to fit behind and under driver • Lower lip to create low point for fuel suction. • 2mm (to support welding) and 5052 aluminum to keep weight low. • Volume of 2.5 gal for minimum fuel requirements and accommodate anti-sloshing foam • Support Parts • Separate fill neck and vent to prevent erroneous fill levels during fueling • PTFE SS Fuel hoses – chosen for its compatibility with high Octane fuels • Durable, chemically and heat resistant • Blank fuel rail for fuel injection • Fuel cell safety foam – a modification in sloshing control from baffles • Tank will be fabricated from donated aluminum from Bauer Compressors, all other parts will be commercially purchased

  46. Exhaust Kyle Brady

  47. Exhaust • Carries waste gas from pistons • Design exhaust system to increase acceleration characteristics • Must be under 110 Db

  48. Exhaust: Design Phase • Stacked configuration insures equal length pipes • Hybrid Tri-Y pairing increases mid-range torque and power after peak torque • Sequential pairing increases scavenging effect

  49. Exhaust: Fabrication Steps • Fabrication has been planned out • Headers will be constructed from pre bent sections • Each complex bend is a series of smaller welded bends

  50. Gearing Joshua Wright

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