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Final Progress Report

David Baker, Adam Baldan, Matthew Grusenmeyer, Evan Jenkins, & Shane Marcks

• An international collegiate competition regulated by the Society of Automotive Engineers • Build an open wheel race car to participate in both design and dynamic competitions • The UD Formula SAE team will compete in the 2011 FSAE West competition in California

http://www.sdsefi.com/techfsae.htm

 Design, Fabricate, and Test a Steel Space Frame Chassis and Fuel System  High considerations to manufacturability  On par with top teams’ performance

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Torsional and Flexural Rigidity

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Weight

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Center of Gravity Height

 Seamlessly Integrate all critical System Components  Resources •

Steel Tubing

 Cost (17kN) Pedal Box Accessibility Manufacturability of Mold and Foam Core Joining Rear Steel Frame to Front Composite Monocoque General Mounting Points of Various Components Pros: - Realizes the structural benefits of monocoque construction - Lighter and more aesthetically pleasing than a space frame with bodywork - Avoids packaging, manufacturing and accessibility challenges of a full monocoque

Cons: - Difficulty of achieving proper pull out strength of critical connections - Limited pedal box Accessibility - General mounting of peripheral components is a challenge

• Composite monocoque structure from firewall forward • Steel space frame utilized for the rear section

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Utilized concept selection Matrices Concepts vs. Weighted Wants, Weighted Metrics, and Constraints

Conclusion 

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Hybrid Monocoque/Space Frame

The hybrid form utilizes the exceptional weight to stiffness properties and the sleek appearance of a composite monocoque, while maintaining the ease of component mounting and adjustability of a steel frame.

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Carbon Fiber Sample Testing ◦ Test panels with donated materials did not have sufficient mechanical properties to allow for use in chassis

◦ Change was made from Hybrid Frame concept to Steel Frame concept  Driven by poor material performance

Wooden Spine Jig

Flat Tube Profile Patterns

   

Weight Center of Gravity Rigidity (Torsional & Flexural) Manufacturability 450hrs

Torsional Test Rig

Torsional Test Rig

Part:

Price: ($)

Notes:

Fuel Pump Fuel Lines and Fittings Space Frame Material Body Work Materials Suspension Mounting Materials Fuel Cell Aluminum Wood For Frame Jig Engine Bushings Bimetal Hole Saws Tube Clamps Body Work Manufacturing Paint for Frame Total:

80 30 350 0

Stock Yamaha Electric Fuel Pump, bracket and o ring

35 60 50 30 40 90

Returned Mounts 3’X3’ 1/16 sheet of aluminum For manufacturing of tube frame 4 Bushings 1 inch hole saws For manufacturing of tube frame

100 50 915

Foam and wood to build mold Rustoleum and Clear Coat

10-20DOM tubing already purchased Donated by CCM