2009_02
DESCRIPTION
and dozens of vendors were all at this year's Silicon Valley International Auto Show. But what would a car show be without race cars? x t With the results gathered, we decided to continue our development of the topside intake. Continued improvement of the prototype increased flow by 3.17%. Further testing will be done on the dyno early this month. 2TRANSCRIPT
Lastmonth,theintaketeamvisitedBobGrommofGrommRacingHeads.GRHisamachineshopdedicatedforhigh‐performancedomesticandimportengines.BobsexpertiseandsupportallowedourteamtoperforminitialtestsontheintakemanifoldprototypesbyusingaSuperFlowflowbench.Thetwoprototypestestedwereourtopsideandsideentrydesigns.Resultsshowedthatthetopsideintakeachieved82.83percentofflowwhereasthesideentryintakeachievedonly76.50percentofflow.Also,theside‐entryintakeshowedfluctuationinthepressurelevel,whichmeantthatflowwasturbulent,somethingwewantedtoavoid.
Withtheresultsgathered,wedecidedtocontinueourdevelopmentofthetopsideintake.Continuedimprovementoftheprototypeincreasedflowby3.17%.Furthertestingwillbedoneonthedynoearlythismonth.
BobGrommsaid,“Eliminatethesquareandsharptaperanglesinsidethemanifold”.Wewilltakeinhissuggestionsandimproveourdesigns.ThanksagaintoBobandGRHforyoursupport.
UP 2 SPEED
AnSAEInternationalnewsletterforSponsors,Faculty,andStudents@SJSU February2009
x t
Thousands of participants, hundreds of cars,
and dozens of vendors were all at this year's Silicon Valley International Auto Show. But what would a car show be without race cars?
This year’s SVIAS hosted a variety of race cars
as well as race teams. In particular, our San Jose State University Formula SAE team, Spartan Racing. Our team unveiled the rolling chassis, which showcased a variety of student designed and built components. Many of our members were on hand to inform individuals about the project and the competition. Engineers and race car designers gave us professional feedback and commended our teams accomplishments and ambition.
We would like to thank Motor Trend Auto
Shows again for sponsoring our team with a vendor booth at this year’s SVIAS.
Please visit: www.motortrendautoshows.com
Formula SAE @
The 2009 Silicon Valley International
Auto Show
2
Inaprojectofthiscaliber,youquicklylearnthattherewill
begooddaysandbaddays.Thesuccessfulteamslearnto
takethingsinstride‐‐usethepositivestomotivateand
propel,andtreatthesetbacksaslearningexperiences.Itis
uptoyoutodecidehowdifficultiesaffectyourprogress.
OneofthemaineventsfortheentireSpartanRacingteam
inJanuarywastheSiliconValleyAutoShow.The
SuspensionTeamworkedaroundtheclocktoensureall
thesuspensionpieceswouldbereadytowithstandthe
scrutinyofprofessionalengineers,machinists,mechanics,
andrecreationalenthusiastsalike.Everythingcame
togethertheweekoftheshow,andtheentireteambeamed
asthecarsatintheconventioncenteracrossfromrace
carsthathadalreadyseenmilesoftracktime.
Then,theflawsstartedshowing.Thefrontwheelscould
notpivotmorethan2degreesduetointerferencewitha
bracket.Aretherotorbuttonsgoingtocontacttheupright
asthewheelsrotate?Wouldthebracketshaveenough
clearancewithintheinsideoftherims?Onebyone,design
flawscametothesurface,andeachoneledtomoreand
morequestionsabouttheexactthingweweresoproudof
only3hoursprior.
FortherestoftheweekendattheAutoShow,someofthe
memberscouldonlyfocusontheseitems.Wetalkedabout
them.Weexaminedthecar,andthentalkedsome
more.Finally,wewereabletobringthechassis
backtocampus,andexcitingthingsbeganto
happenoncemore.
Forstarters,thecarsat.Untouched.Ourteam
wentbacktothedesigns,recalculated
measurements,andhadextensivediscussionson
howtoproceed.Theseflawscameaboutdueto
rusheddesignswithoutproperexaminationand
review.Reluctanttomakethesamemistake
twice,theSuspensionTeamhadmultiplepeople
brainstormideasonhowtofixeachproblem.The
finalsolutionswerealsomulledoverbyafew
memberstomakesureeverythingwasdouble‐
checked.Then,finally,thesuspensionpieceswere
disassembledandthemillsandlathesstarted
turningagain.
Noracingteamcancompletelyavoidfailure.Even
MichaelSchumacherhadaDNFonceinawhile.
Theoneswhowinmorethanloseinthelongrun
learnfromtheirmistakesandavoidmakingthem
again.TheSuspensionTeamispartofthis
categoryandhasimplementedchangessuchas
informaldesignreviewsandadditional
simulationinCADtoensurefuturedesignshave
moresuccess.
Shocking
3
Intake,combustion,power,andexhaust,soundfamiliar?
It’stheinfamousOttocycle.
Ourintakedivisionhasbeendevelopingandtestingtheir
prototypedesignsandhavebeenworkingcloselywith
GrommRacingHeads.Wewillcontinuetotestprototype
designsthroughout
themonth,whichwill
helpusdesignan
optimizedintake
system.
Ourengine
managementdivision
hasbeengettinginto
gear.Duringthe
SiliconValley
InternationalAutoShow,afewofourteammembers
workedrigorouslyongettingour2003CBR600F4i
powerplanttocombust.Fortunatelyforus,theirefforts
paidoffasthesparksignitedtheair/fuelmixtureand
producedmuchneededmotivationandenergy.Thatis,
workenergy.Afterallsystemswerechecked,anddouble
checked,ourteamshiftedthetransmissionintogear.
Workenergynowproduced,rotationalenergy.
Thetrailingedgeofthiscycleleadstoourexhaust
system.Ourexhaustdivisionhasdonetheir
homework,calculations,anddesigns.Theyare
nowlookingforavendorwillingtodonatesome
materialforourexhaustmanifoldandsystem.
Anothercompanyhasagreedtodonatesometime
tomanufactureourdesignoncewehaveit
finalized.
Tohelpexplainwhatisgoingoninsidetheengine,
theteamputtogetheraLabVIEWinterfaceto
measureoilpressure,exhaustgastemperature,
RPM,watertemperature,andmore.Calibrations
ofeachsensorwillbedonetomakesureweare
gettingcorrectandusefuldata.
Oncethetestinganddatacollectingaredoneon
thedyno,wewillplacethetunedmotorontothe
chassis.Atthesametime,wewillbeinstallingour
rotationalassembly.WewilluseaTorsen
UniversitySpecialdifferentialhousedinourown
custom‐designedhousing.Asprocketandchain
willdrivethedifferential.Duetotimeconstraints
andlimitedmachiningcapabilities,wepurchased
axlesandCVjointsfromTaylorRaceEngineering.
Afterallthatissaidanddone,wewillbeshifting
gearsoffthedynoandintothelight,theshiftlight.
mOTTOcycle
4
Designandconstructionoftheracecarisnotsolely
motivatedbyperformance‐vehiclecostmustbe
consideredduringthedesignandconstructionphases.
Oneoftheobjectivesofthecompetitionistocreatea
small‐scaleformulastyleracecarthatperformswell,
butalsodoesn’tbreakthebank.Costconsiderations
becomeevenmoreimportantwhenfundingisnot
readilyavailable.Inthecurrenteconomicclimate,
minimizingcost,whilemaintainingorincreasing
performancebecomesanecessity.
Todeterminethecostofthecar,costreportsmustbe
generatedandcompiledbasedonthepartsand
materialsusedtoconstructthevehicle.Intheprocessof
generatingthesecostreports,costsversusbenefit
analysisofmanycomponentsandconstructionmethods
areperformed.Theseanalysesallowedourteamto
determineifthemonetarycostofacomponentwas
worththeincreaseinperformance.
Inordertoaccuratelyestimatethecosttoproducethe
car,wemustestimatemanyvariablessuchasthe
volumeofmaterialremovedwhendrilling,lengthof
weldsmadetotheframe,andeventhenumberofturns
ittakestofastenabolt.Allthesethingsandmany
othersfactorintothefinalcostofthecar.Keepingtrack
Pro E to SolidWorks, who says engineers can’t do artwork? From free body diagrams and CAD design to websites and graphic designs. From engineering to business, a few of our members have been able to balance the two disciplines diligently. Working on projects such as BE U.NITED and Formula SAE, our student members have been introduced to another degree of freedom. Our involvement in such projects gives us practical real world experiences that better prepares us for the industry.
Cha-Ching
ofallthesecostsisanenormoustaskthatcannotbe
accomplishedbyasingleindividual.Inorderto
spreadtheworkload,thecostreportisdividedinto
subsections,whereeachteamisresponsibleforcost
reportsrelatingtotheirportionofthevehicle.
SAEInternationalrequiresthatallparticipantsuse
thesamepriceformaterialsandcomponents.This
allowsforthecarcosttobecomparedfairly,
regardlessofwhereintheworldthecarwasbuilt.To
dothis,standardizedpricingformaterials,
components,manufacturingprocedures,andmany
othercostsaresetbySAEInternational.These
pricingspreadsheetscontainvariousitems,suchas
thecostperkilogramof4130chromolysteel,
machiningcostformachinemillingofaluminum
wheelhubs,andlaborcostsofhandscrewingabolt
intoplace.
Thecostreportisalsopartofthestaticeventsthat
judgeswillscore.Ourteammustsubmitthereport
nolaterthanMay4th2009.Duringthecompetition
judgeswillcomparewhatwaslistedinourcost
reporttoourcompletedvehicle.Anydiscrepancyof
componentsormaterialsusedornotwillleadto
pointdeductionsandmayevenleadtoanegative
score.
Please visit: www.fsaeonline.com
SJSU Diversity
R S RACING SPARTAN
www.spartanracing.net
5
Newsletter Staff: Editor: Randy Floresca Assistant Editor: Ken Lau Contributors: Benoit Belley Tony Lee Douglas Tse
Upcoming Events
February 1, 2009 12pm Available online
FSAE Structural Equivalency Form due
February 23-25, 2009 8am – 5pm San Jose State University
Intermediate GD&T for Design, Manufacturing & Inspection
March 1, 2009 12pm
See Section 3.3.6.3 of rulebook FSAE Impact Attenuator Data due
March 11, 2009 12pm
See Section 51.2.1 of rulebook Mini Baja Cost Report due
March 11, 2009 6pm - 8:30pm
Engineering Building E287 Aero Engineering Excellence
Presented by Larry Rinek
March 23, 2009 12pm See Section 51.1.1 of rulebook Mini Baja Design Report due
March 23-27, 2009
Spring Break
Composed Ourteamhasdesignedsomegreatideasforourcar's
bodyandhowthepanelsectionswillfittogether.
Withthecarquicklycomingtogether,thechassisteam
hasbeengearinguptomakeanawesomebody.We
areworkingtoacquirematerial,specificallyfiberglass,
foam,andresin.Dr.KevinSawyerwillbedonating
morefineweavefiberglasstoaddtothefiberglassthat
hehasalreadykindlygivenus.Ourteamwillalso
receivefiberglassrovingandchopstranddonatedby
Dr.RichardChungfromtheChemicalandMaterials
EngineeringDepartment.
Theprocessofcreatingthebodywillalsorequirefoam
tomakethepositivemoldofthebody.Ourcurrent
estimatesshowthatwewillneedapproximately45
cubicfeetoffoamtomakethebody.TheConcrete
CanoeTeamfromtheCivilandEnvironmental
EngineeringDepartmenthasalreadydonatedsome
foamtogetusstarted,howeverwestillneedalot
morefoamandaretryingtofindasponsortoprovide
theseresources.
Thisisallgreatnews,butthefiberglassweavewould
notbemuchwithoutitsresintoholditalltogether.
TheChassisTeamwillbeginconstructingthebody
soon,soasponsorshipforresinwouldhelpus
concentrateonotherareas.Theteamwillneedatleast
twogallonsofresin.Wearelookingforwardto
developingabodythatwillenhancetheappearanceof
analreadygreatcar.
6
Thank You to our Sponsors
SAEInternationalSJSUStudentChapterRubenDelgadillo,VicePresident(925)550‐[email protected]
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818 CRISTICH LANE
SUITE 1
CAMPBELL, CA 95008
T: (408) 796-7949
F: (408) 796-7950
C: (408) 438-8237
AMEEN SAJJADI OWNER / CO-FOUNDER
818 CRISTICH LANE
SUITE 1
CAMPBELL, CA 95008
T: (408) 796-7949
F: (408) 796-7950
C: (408) 438-8237
AMEEN SAJJADI OWNER / CO-FOUNDER
818 CRISTICH LANE
SUITE 1
CAMPBELL, CA 95008
T: (408) 796-7949
F: (408) 796-7950
C: (408) 438-8237
AMEEN SAJJADI OWNER / CO-FOUNDER
T: (408) 796-7949
F: (408) 796-7950
C: (408) 438-8237
818 CRISTICH LANE
SUITE 1
CAMPBELL, CA 95008
GP WWW.GPBIKEPARTS.COM
BIKE PARTS
AMEEN SAJJADI OWNER / CO-FOUNDER
SPORTBIKE PARTS & SERVICE SPECIALISTS
818 CRISTICH LANE
SUITE 1
CAMPBELL, CA 95008
T: (408) 796-7949
F: (408) 796-7950
C: (408) 438-8237
AMEEN SAJJADI OWNER / CO-FOUNDER
818 CRISTICH LANE
SUITE 1
CAMPBELL, CA 95008
T: (408) 796-7949
F: (408) 796-7950
C: (408) 438-8237
AMEEN SAJJADI OWNER / CO-FOUNDER
818 CRISTICH LANE
SUITE 1
CAMPBELL, CA 95008
T: (408) 796-7949
F: (408) 796-7950
C: (408) 438-8237
SAEInternationalSJSUStudentChapterRandyFloresca,President(510)206‐[email protected]
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