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Formula Car 2012 Team Members. Background. FSAE is collegiate competition in created race ready vehicles. Vehicles are student designed and fabricated . Competition in Detroit, Michigan May 9-12, 2012. Cars are tested in:. Static Events: Presentation 75 Engineering Design 150
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Background • FSAE is collegiate competition in created race ready vehicles. • Vehicles are student designed and fabricated. • Competition in Detroit, Michigan May 9-12, 2012. • Cars are tested in: • Static Events: • Presentation 75 • Engineering Design 150 • Cost Analysis 100 • Total: 325 • Dynamic Events: • Acceleration 75 • Skid-Pad 50 • Autocross 150 • Fuel Economy 100 • Endurance 300 • Total: 675
Frame • Frame was nearly complete, but rule requirements forced drastic changes to the frame.
Structural Analysis • Because of extensive modifications, frame had to be modeled in PATRAN again.
Suspension • Front and Rear are fully independent suspension setups. • Fabricated from solid round bar. • Front coil-overs mounted in driver’s compartment. • Rear coil-overs mounted horizontally along frame connected by bell-cranks
Body Work (Aero and Seat) • Carbon Fiber/Corecell Foam Seat Construction • Wet laid 6 ounce carbon fiber
Body Work (Side Panels/Nose) • Doors constructed of 1/8 inch core-cell foam laminated with carbon fiber • Remaining work is final preparation of the front nose detail before carbon fiber can be laminated • Body filler must be used to fill in the gaps in the foam • Much of the body work needs to be modified due to frame changes.
Pedals & Controls • Pedal assembly has been fabricated and currently being plumbed. • Shifter & clutch handle have been fabricated and mounted.
Engine • Using 600cc engine out of Suzuki GSX-R motorcycle • Rules limit engine size to 610cc. • New exhaust was fabricated • Because of a relatively new motor and frame design, team had to fabricate a one-off exhaust system • Modified the oil pickup to fit custom oil pan
Intake Manifold • 4” injector collar(s) • 45° Elbow(s) • Carbon Fiber Manifold • Carbon Fiber Reducer • Restrictor Plate • Fabrication is in process
Cooling system • Using a custom fabricated radiator that hangs off driver's side of vehicle and will pump distilled water through engine • Location was chosen because of lack of space and radiator needs to be in direct flow of air • Has fan mounted to backside to assist in further air flow • Catch can mounted behind radiator to catch any excess water
Logistics • Responsible for paperwork, website, and travel • Competition & class documents • Design report and cost report most important • Worth 150 and 100 points towards total score • Design Report • Gave reasons for why the car was designed • Judges aren’t interested in number crunching
Logistics • Cost Report • Most time consuming • Individual costs (material, tooling, labor) for each individual part of the vehicle • Summed up to give total estimate for competition • $21,841.96
Next Step • Team is heading to Virginia International Raceway for testing, April 28& 29 • Vehicle needs to be completed in next couple of weeks in order to meet competition deadline. • Team is extremely close to being ODU’s first entry into competition in years.
