XTUP 2 SPEED

An SAE IntErnAtIonAl nEwSlEttEr for SponSorS, fAculty, profESSIonAlS, And StudEntS

VolumE 2: ISSuE 15dEcEmbEr 2009

SpotLight

Our SAE International student chapter would like to thank all of our SPONSORS for the 2009-2010 academic year. Thanks to your support, our members have the opportunity to work on the most challenging yet most re-warding projects that universities and colleges from all around the world can take a part in: Formula SAE, Formula Hybrid, and Baja SAE.

Your support and contributions allow our student members to develop skills that better prepare them for their curriculum and the work field. From utilizing engineering prac-tices such as Computer Aided Design, Finite Element Analysis, and Designing for Manu-facturability to executing business practices like management, marketing, and networking, our student members will be the top of their class and the best prepared graduates for their respective industries.

Thank you for your support and thank you for giving us this opportunity.

BAE Systems has contributed more than $15,000 in sup-port of our Formula SAE, Formula Hybrid, and Baja SAE Teams.

For more information about BAE Systems please visit:www.baesystems.com

An SAE International SJSU Spartan Platinum Sponsor

Inland Metal Industries has donated more than $2,500 in raw material to support of our Formula SAE, Formula Hybrid, and Baja SAE Teams.

For more information about Inland Metal Industries please visit:www.inlandmetal.com

SAE International SJSU Gold Sponsors

Sims Metal Industries has donated more than $2,500 in raw material to support of our Formula SAE, Formula Hybrid, and Baja SAE Teams.

For more information about Sims Metal please visit:www.simsmm.com

The Santa Clara Valley IEEE section has contributed $2,500 to support our first Formula Hybrid team.

For more information about the SCV IEEE section please visit:www.ewh.ieee.org/r6/scv/

“top of their class and the best pre-pared graduates for their respective industries.”

Motor Trend Auto Shows, LLC has donated a booth to our SAE International SJSU student chapter for the 2010 Silicon Valley International Auto Show. We will be display-ing our award winning 2009 Formula SAE racecar as well as our 2010 Formula SAE and Hybrid chassis.

This four-day event can draw close to 200,000 participants. It is a great way for our student members to show the com-munity what we can accomplish at San Jose State Univer-sity and it also gives us a chance to market and advertise for our generous sponsors.

For more information about the 2010 Silicon Valley International Auto please visit:www.motortrendautoshows.com/sanjose

Our SAE International student chapter had the opportunity to tour the FOX Racing Shox headquarters in Watsonville, CA. FOX Rac-ing Shox is an industry leader in the design and development of high performance suspension products for snowmobiles, mountain bikes, atv’s, motorcycles, and off-road cars and trucks.

The highlights during the tour included design reviews of their sus-pension products, a visit through their production machine shop, and a peek at their assembly line.

For more information about FOX Racing Shox please visit:www.foxracingshox.com

Foxtour

NeatideaSFair

The Entrepreneurial Society at SJSU hosted their fifth annual Neat Ideas Fair. The Neat Ideas Fair allowed students to show-case their creativity and entrepreneurial talent through innovative “Neat” business ideas. Some of their ideas included a Hybrid Hemodialysis Device, a Carry On Scooter, and an alarm clock that literally forces you to get up.

Our Formula Hybrid and Formula SAE teams used this opportunity to recruit new members and to inform potential sponsors, faculty, and students about our projects. For more information about the Neat Ideas Fair please visit:www.cob.sjsu.edu/SVNIF/

Congratulations to Ammar Khan, Johanna Knudsen, and Joey Pen-niman for your accomplishments. Thank you so much for being a part of the SAE International SJSU fam-ily. We wouldn’t be where we are today if it wasn’t for your involve-ment, dedication, and willingness to learn. We wish you the very best in your careers as mechanical engineers, industry professionals, and SJSU alumni.

CoNgradS!

CoLLegehighLightSAmmar Khan

2009 FSAE impact attenuator • designer and manufacturerPi Tau Sigma Vice President• Involvement in College of Engi-• neering outreach programs

Johanna Knudsen2009 Formula SAE Chassis • designer and manufacturer 2010 Baja SAE Co Captain, • designer, and manufacturerStudent mentor•

Joey Penniman2009 & 2010 Formula SAE • chief Engineer, suspension designer, and manufacturerStudent mentor•

AmmAr

JohAnnA

Joey

Our 2010 FSAE frame has been underway since the end of November and should be completed in two weeks. The design of the frame however had been an ongoing process since the beginning of the fall semester. Our design objectives for this year’s frame included the following; pass the rules set forth by SAE International (including several new ones), manufacturable in house, more ergonomic for all our drivers, and design it to have an appropriate tor-sional rigidity value while reducing its weight. Small changes were made to achieve these goals how-ever, the focus was on torsional rigidity and reducing weight.

Our suspension team has designed most of their components and has also manufactured the already completed designs. Our powertrain team has manu-factured an engine stand and has decided to over-haul their CBR600 F4i motorcycle during the winter break. More to come in January...

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Our 2010 Baja SAE team has been working ex-tremely hard the entire semester. From designing a completely new frame to developing a custom gear box, our Baja team is gearing up to win the competition in May. Not only has the team shown great work ethic by designing and manufacturing the frame sooner than any of our previous Baja teams, the team captains Darren Schwald and Johanna Knudsen, have spent countless hours teaching and mentoring our underclassmen engineering and manufacturing skills that classes just don’t teach.

Our Baja team sees and understands the value of working on projects of this caliper and is not afraid of teaching any of our student members that want to learn.

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Storm Copper Components, CO. specializes in manufacturing custom copper components from bus-bars and printed circuit board connectors to flexible connectors and electrical insulators. Storm Cop-per Components, CO. has been in business since 1990 as a dedicated copper supplier and ships over 17,000 copper connectors per day to OEMs around the world.

Storm Copper Components, CO. has agreed to sponsor our Formula-Hybrid team with all of our busbar needs. This sponsorship is vital to our team which is sending over 60 kilowatts of power to the drivetrain. We can’t thank them enough for their sup-port.

For more information please visit:www. stormcopper.com

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Students, when tasked with designing a component, often fail to take manufacturing into account. Much too often do we see designs that are extremely lightweight, strong, and impossible to manufacture. The truth is, designing is an iterative process. We learn by doing, and nothing hammers that point home more than find-ing out that your wonderfully designed part just can’t be manufactured. We have learned this lesson the hard way. Having only two manual lathes and manual mills, and one CNC to manufacture with, we are very pressed to consider manufacturing when designing our parts. This turned out to be a fatal flaw when many frame tubes needed to be changed or notched “funny” in order to make them work. This flaw also effected our ability to manufacture our suspension pickups which ended up being unmanufacturable, and again when we found that copper busbars are not carbide-bit friendly. In all of these situations, our designs were changed so that they could be manufactured.

As aspiring engineers, we are ultimately thankful for this. Our SAE International SJSU Student Chapter recently took a tour of Advanced Machine Technol-ogy (AMT) Inc. During the tour, we learned buckets about a concept called design for manufacturing. The truth is that in industry many engineers don’t know how to save manufacturing costs on a part by making the manufacturing processes easier. The engineers who understand the concept are ahead of the game because it leads them to make a part based on simpler designs, less headaches, and reduced costs.

Most engineers wouldn’t get this type of hands-on learning experience until they hit industry and learn the hard way. Thankfully for us, we have taken it in stride and now understand and have experience with a whole new layer of product design, designing for manufac-tureability.

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Teams are defined by the goals that they hope to achieve. In an automotive racing environment, it is crucial to have clearly defined goals which unite all team members and guide the design process. This provides a clear front on which to base the majority of team decisions.

Some goals in this application can be considered “constants”. A team will always want a lighter car. A team will always want a stiffer car. A team will also always want to have a reliable component versus an unknown. These are the types of goals which guide basic design decisions, and for the most part can be used to bond a team. Another type of goal is the immeasurable. Some teams just want to finish their vehicle by competition time. Some teams want to win a particular event and some teams just want to have fun along the way.

The point is that no matter what the goal is, it is important for a team to buy-in to the same set of goals in order for progress to occur. If one team member wants more horsepower at the cost of added weight, and another team member chooses to sacrifice bot-tom end power in favor of saving the weight (e.g. adding a forced induction system), the team has ultimately ended up with a car that is heavier and potentially inreliable. Very rarely do compromises turn out to be champions. All major sports dynasties have won because they lived to a common system or goal.

The downside to this is that a team can be comprised of all-stars, yet fail if they do not all strive for the same higher goal. A team can not be defined by the individual or the component, but rather by the goal that it strives for.

Headquartered in Bethesda, MD, Lock-heed Martin is a global security company that employs about 146,000 people worldwide and is principally engaged in the research, design, development, man-ufacture, integration and sustainment of advanced technology systems, products and services.

Lockheed Martin has joined our Formula Hybrid team and became a bronze spon-sor by contributing to our team’s bat-tery management system. We are very thankful for their support and look for-ward to developing this new relationship.

For more information please visit:www.lockheedmartin.com

hAppy holidAyshAppy holidAysto you and yours!to you and yours!From SAE International at SJSUFrom SAE International at SJSU

Formula SAE Formula Hybrid

thegoaLBy: JoSh hogaN

Thank You to Our Sponsors upcomIng EVEntS

December 18 - January 26Formula SAE

Formula HybridBaja SAE

Fabricating in the ShopEngineering Building

Room E123

December 25, 2009Christmas

January 1, 2010Happy New Years

January 7-10, 2009 10am-10pmSilicon Valley International

Auto ShowSan Jose McEnery Center

January 26, 2010Spring Semester Begins

SJSU

February 4, 2010Meeting with Don Beall

Engineering BuildingRoom E123

March, 2010Presentation By:

Larry RinekEngineering Building

Room 285

For more events and updates please visit:www.engr.sjsu.edu/sae/calendar.html

Newsletter StaffEditor/Writer: Randy FlorescaWriters: Josh Hogan Andrew Robertson

Randy FlorescaPresident

SAE International SJSU(510) 206 - 3229

randyfloresca@gmail.com

atSan Jose State University