DIFFERENTIAL FOR FORMULA SAE RACE

CAREML4551 Ethics and Design Project Organization

Team 09

Shivana MahesUber Mantovani

Alessandro Tasca

SUMMARY Problem statement

Project description Motivation and goals

Division of Responsibilities Project Timeline Goals Design Considerations Design Alternatives Standards Global Learning Conclusion Questions

PROBLEM STATEMENT Design differential and components for the

2016 FSAE competition Components include housing, mounts, sprocket

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MOTIVATION AND GOALS

Motivation FSAE is a prestigious

global competition Top engineers attend

and judge entries

Goals Optimize differential for

FIU’s car Optimize power transfer

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DIVISION OF RESPONSIBILTIES

Shivana Mahes Calculation and design of housing and spacers,

Solidworks modeling and simulations, written documents

Uber Mantovani Calculation and design of sprocket, springs, and

friction plates, Solidworks modeling and simulations Alessandro Tasca

Calculation and design of gears, prototyping, and manufacturing

PROJECT TIMELINE

GOALS

Reduce weight from current differential by 15%

Maintain current torque bias ratio of 4:1

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DESIGN CONSTRAINTS 2016 FSAE rules 45° tilt test-differential cannot leak Withstand engine specifications Location and size of sprocket Safety and reliability Dimension of current drive axle shafts and

CV joint angle Costs

DESIGN CONSIDERATION Location of

differential Engine development Interchangeable

sprocket

DESIGN ALTERNATIVE 1

Alternative 1 Differential using gears only

Simple design Utilizes only mechanical parts

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DESIGN ALTERNATIVE 2 Alternative 2

Differential using gears and friction plates Added weight from friction plates is

negligible over alternative 1 Friction plates can wear out

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DESIGN ALTERNATIVE 3

Alternative 3 Differential using gears and spring-

loaded friction plates Capable of achieving highest torque

bias ratio of all 3 alternatives More complex than all 3 alternatives Increases cost of manufacturing and

maintenance

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DESIGN ALTERNATIVE 3

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SURVEY OF STANDARDS

American Society of Testing and Materials Specific standards to be used depend

on material selected

American Gear Manufacturers’ Association Standards apply to gears, couplings,

and power transmission components

SURVEY OF STANDARDS

Society of Automotive Engineers Bolts and viscosity of lubricants

GLOBAL LEARNING

Design for manufacturability in various parts of the globe

Use of universal units (SI/US)

Manual in multiple languages

Cost analysis for different regions in different currencies

CONCLUSION

Design, manufacture, and assemble differential for 2016 FIU Formula SAE car

Optimize drivetrain Reduce weight Maintain current TBR

QUESTIONS