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PROJECT MANAGEMENT AND DESIGN II

MAE 435 FINAL REPORT

April 21st, 2015

Editors

Ellitt Cl!"is Mi#$%&l P&r'i(s

Authors

R)&rt *+r(s

&it$ C%-p

T.l&r Cr%/&(

Ri#%r" E(ri+&

J+sti( Fr&ri#'sLl%ir

C$%rl&s "'i(s

M%r' l&p&is

.l& L!&

J$(%t$%( M&%"r

*r%("( N%pi&r

Js&p$ P&t&rs(

Tr&/r R%-&.


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Project Advisors

Dr S&)%sti%( *%!%)

Dr Cli( *rit#$&r

Mr N%t$%( L&+t'&

TABLE OF CONTENTS

1 ABSTRACT........4

2 INTRO!CTION......"

# RI$ETRAIN........%

31 INTROD6CTION777777777777777777777777778

32 METODS77777777777777777777777777778

33 RES6LTS777777777777777777777777777779

4 S!SPENSION.......11

41 INTROD6CTION777777777777777777777777711

42 METODS777777777777777777777777777713

43 RES6LTS777777777777777777777777777714

" BRA&ES............1'

51 INTROD6CTION77777777777777777777777771:

52 METODS7777777777777777777777777771:

53 RES6LTS777777777777777777777777777718

' INTA&E.........1(:1 INTROD6CTION77777777777777777777777771;

:2 METODS AND RES6LTS7777777777777777777771;

% AERO)NA*ICS...2#

81 INTROD6CTION777777777777777777777777723

2


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82 METODS777777777777777777777777777723

83 RES6LTS7777777777777777777777777777724

+ ISC!SSION....2"

LIST OF FI,!RES

Fi+r& 1< Di==&r&(ti%l M+(t

Fi+r& 2< S+sp&(si( C-p%ris(

Fi+r& 3< S+sp&(si( C%l#+l%trFi+r& 4< R#'&r M"&l

Fi+r& 5< R#'&r CAD "r%!i(Fi+r& :< Fr(t C%lip&r *r%#'&tFi+r& 8< Fr(t Rtr C%rri&r

Fi+r& 9< R&%r C%lip&r *r%#'&t

Fi+r& ;< R&%r Rtr C%rri&rFi+r& 10< R&%r *r%'& Ass&-)l. I()%r"

Fi+r& 11< I(t%'& M"&l

Fi+r& 12< F+ll i(t%'& =l! %(%l.sisFi+r& 13< T$rttl& )". =l! %(%l.sis

Fi+r& 14< Si"& P" CFD

LIST OF E-!ATIONS

E+%ti( 1< G&%r R%ti E+%ti(E+%ti( 2< R+((&r L&(t$ E+%ti(

3


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1 Astr/ct

The 2015 Formula SAE (Society of Automotive Engineers)

competition reuires stu!ents to fa"ricate an! test an open#$heele!

racecar of their o$n !esign% The overall goal for the &l! 'ominion

niversity Formula SAE team is to place higher at the 2015 competition

than the team place! in 201* the team+s "est ,nish as of yet% This

o"-ective $ill "e achieve! through various improvements implemente! in

the 2015 car% The inta.e manifol! $ill have runner length an! plenum

!imensions !etermine! using a program $ritten in /ATA (/athor.s*

atic.* /A)% Aero!ynamics $ill incorporate a rear !i4user an! "o!y panels

to minimie !rag% oth front an! rear suspension $ill utilie a push#ro!

system* as oppose! to last year+s rear pull#ro! system% This $ill alleviate

the "in!ing at the roc.er arms an! allo$ the suspension to utilie more of

its travel% The !i4erential carrier has "een improve! to han!le the forces

applie! !uring operation% The gear ratio in the !i4erential has "een

a!-uste! to allo$ for full use of the 6#spee! transmission% To improve

"ra.ing* all four $heels $ill each have their o$n rotor an! caliper

com"ination% Also* a proportioning valve $ill "e incorporate! for

a!-ustment of front to rear "ra.e "ias%


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2 I0troductio0

I( 2014 t$& Ol" D-i(i( 6(i/&rsit.>s ?OD6@ Fr-+l% SAE t&%- s&t t$& s#$l rr"

pl%#i( t$irt.s&/&(t$ +t = (& $+("r&" %(" (i(& #-p&ti( t&%-s Fr t$& 2015 &(tr., OD6

$%s "i"&" t =#+s ( =i(&t+(i( t$& "&si( = l%st .&%r>s #%r $il& t$& 2014 #%r p&r=r-&"

!&ll t$&r& %r& s&/&r%l %r&%s t$%t !ill )& r&"&si(&" =r t$& 2015 #%r

T$& 2014 #%r $%" si(i=i#%(t pr)l&-s !it$ /&$i#l& $%("li( T$& =r%-& !%s r&"&si(&"

( t$& 2014 #%rB $!&/&r, t$& s+sp&(si( !%s #%rri&" /&r =r- t$& 2013 #%r C-)i(i( t$&

s+sp&(si( %(" =r%-& =r- s&p%r%t& .&%rs r&s+lt&" pr "ri/i( #$%r%#t&risti#s s+#$ %s

+("&rst&&r, )+-p st&&r, %(" &ssi/& !$&&l tr%/&l i( %""iti( t -$%(i#%l )i("i( = t$& r&%r

r#'&r %r-s T$is .&%r !& $%/& p+t %( &-p$%sis ( i-pr/i( t$& /&$i#l&>s $%("li( T

-%i-i& tir& #(t%#t t$r+$ #r(&rs, #%-)&r !%s %""&" t t$& "&si( = t$& =r(t p+s$ r"

s.st&- T$& r&%r s+sp&(si( !%s #$%(&" t % p+s$ r" =r- t$& pr&/i+s p+ll r" "&si(

A##r"i( t t$& Fr-+l% SAE r+l&s, t$& )r%'&s -+st )& #%p%)l& )&i( l#'&"

si-+lt%(&+sl. Pr&/i+sl., OD6 +s&" % si(l& r&%r )r%'& t$%t l#'s )t$ r&%r !$&&ls t$r+$ t$&

"i==&r&(ti%l T$& 2015 #%r +tili&" =+r!$&&l "is# )r%'&s t pr/i"& i-pr/&" stppi( p!&r

%(" &($%(#&" "ri/&r #(trl T -&&t t$& FSAE r+l& r&+iri( t! i("&p&("&(t )r%'i( s.st&-s,

OD6 $%s +s&" % s&p%r%t& =r(t %(" r&%r $."r%+li# )r%'& s.st&- A prprti(i( /%l/& !%s %""&"

t t$& r&%r )r%'& s.st&- %ll!i( )r%'& )i%s %"+st-&(t

T$& =i(&t+(i( #(ti(+&" !it$ t$& i(t%'& "&si( =r t$& 2015 #%r T$& pr&/i+s "&si(

r&s+lt&" i( p&%' p!&r )&i( &(&r%t&" i( % l! RPM r%(& T$& (&! i(t%'& r+((&r l&(t$s !&r&

#%l#+l%t&" t %#$i&/& p!&r i( t$& "&sir&" r%(& A""iti(%ll., t$& pl&(+- /l+-& !%s i(#r&%s&"

t pr/i"& %"&+%t& %ir=l! t t$& &(i(&

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T$& %&r".(%-i#s p%#'%& !%s #-pl&t&l. r&"&si(&" =r t$& 2015 #%r T$& si"&p" %("

"i==+s&r "&si( !&r& #$%(&" t i(#r&%s& "!(=r#& i( #r(&ri( !$il& -i(i-ii( "r% ( t$&

str%i$ts $&( t$& (s& #(& !%s r&=i(&", t$& (s& !%s r+("&" t %ll! =r s-t$ =l! /&r

t$& /&$i#l&>s )".

T$& %l = t$& 20142015 Fr-+l% SAE t&%- is t $%/& OD6 pl%#& $i$&r t$%( t$& 38t$

=i(is$ =r- l%st .&%r T %##-plis$ t$is !& +s&" l%st .&%r>s #%r %s % -"&l = !$%t !r's !&ll

L'i( %t t$%t -"&l !& '&pt !$%t !r'&" %(" =#+s&" ( prr&ssi( i( %r&%s t$%t s&&-&"

!&%' it$ t$&s& "&si( #$%(&s !& %r& #(=i"&(t !& !ill -&&t +r %l

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# rivetr/i0

#.1 I0troductio0

T$& "ri/&tr%i( $%s s&/&r%l #-p(&(ts i(#l+"i( t$& trip"s, %l&s, %(" r&%r &(" &%r It

is #r+#i%l =r &%#$ pi& t )& prp&rl. i(st%ll&" %(" #+t r pl%#&" i( its "&si(%t&" l#%ti( =r

pti-%l p&r=r-%(#& T$& trip" is % i(t t$%t $%s %( i((&r spli(&, !$i#$ #(sists = t&&t$ (

t$& i(si"& +s&" t #((t t %( %l& s$%=t 1 T$& Fr-+l% SAE #%r>s %l& %ss&-)l. is %ls

/it%l "+& t t$& #-p(&(t #/&ri( -+ltipl& %r&%s = p&r=r-%(#& = t$& #%r A #-pl&t& %l&

%ss&-)l. !r's !it$ t$& "i==&r&(ti%l %(" st+) %l&s t -%'& t$& !$&&ls rt%t& *+il"i( %

r&li%)l& %(" &==i#i&(t %l& %ss&-)l. #%( =%il "+& t s-%ll -is#&ll%(&+s t%s's t$%t #%( )&

/&rl'&" "+ri( "&si( %(" =%)ri#%ti( 1,2 A(t$&r -%i( r&+ir&-&(t =r -%i(t%i(i( t$&

%l& %ss&-)l. is $%/i( t$& "i==&r&(ti%l )r%#'&ts s+r&" t !it$st%(" &(+$ =r#& !it$+t

)&("i( r =%ili( Appl.i( =i(it& &l&-&(t %(%l.sis ?FEA@ t t$& )r%#'&ts i/&s "%t% t "&si(

t$& "i==&r&(ti%l -+(ts t -%i(t%i( rii"it. =r- t$& %pprpri%t& =r#&s 3 I( r"&r t #%l#+l%t&

t$& &%r r%ti =r % Fr-+l% SAE #%r, =i("i( t$& tp sp&&" %(" &%r r%tis = &%#$ &%r i( t$&

-tr i/&( !ill %ll! t&%-s t #r&%t& % &%r r%ti #%l#+l%tr s$!( i( &+%ti( 1

7


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#.2 *ethods

A spr&%"s$&&t #%l#+l%tr !%s #-pl&t&" t #(=i+r& t$& &%r r%tis %(" -il&p&r$+r

?-p$@ = &%#$ &%r %t &%#$ r&/l+ti(p&r-i(+t& ?rp-@ t$%t t$& &(i(& !ill pr"+#& i( t$%t i/&(

&%r T$& &+%ti( t #%l#+l%t& t$%t is t$& =ll!i(s t&%- #$s& % $i$&r &%r r%ti #-p%r&" t l%st .&%rs 3125


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#%l#+l%t& t$& FEA ( t$& "i==&r&(ti%l #%rri&r s$!&" t$%t it s$+l" (t =%il "+ri( l%"i(

+("&r /ir+s t&sti( s$!( i( Fi+r& 1


S$!i( % =r#& = 2000 N&!t(s ( t$& "i==&r&(ti%l #%rri&r %)/& pr/&s t$& rii"it.

= &%#$ sti( i(#l+"i( t$& %l+-i(+- )r%#'&t !it$ $l&s "rill&" i(t it T$& p%rts =r

#-pl&ti( t$& )+il" = t$& #%r $%/& )&&( p+r#$%s&" %(" %ll $%/& )&&( "&li/&r&" t t$&

&(i(&&ri( "&p%rt-&(t T$& %l&s, trip"s, ##lips, r" =ill&rs, pl%sti# r" &("s, r+))&r #/&rs,

%(" spri(s $%/& )&&( "&li/&r&" =r- t$& s%-& /&("r, %(" !$&( t$& "i==&r&(ti%l %(" r&%s& is

"&li/&r&" t$& "ri/&tr%i( =%)ri#%ti( !ill st%rt T$& trip" s&t+p #(sists = %l&s t$%t %r& -%"&

= % 4140 %ll. $ll! st&&l t+)& t$%t !ill $%/& % s-%ll t! i(#$ spri( !it$ % pl%sti# =ill&r r"

%(" t! pl%sti# r" &("s %tt%#$&" =r t$& %l&s i( r"&r =r it t =l%t> )&t!&&( t$& +pri$t %("

"i==&r&(ti%l T$& pr&/i+s t$r&& =r-+l% #%rs %t OD6 $%" t$& s%-& trip" s&t+p %(" ((& =%il&"

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"+& t str&(++s =r#&s %(" tr+&s %""&" t t$& %ss&-)l. D+& t t$& s+##&ss = t$& s&t+p, !&

#$s& (t t #$%(& t$%t prti( = t$& r%#& #%r =r t$is .&%r>s #-p&titi( "+& t its rii"it.

%(" $l"i( +p %%i(st &%#$ pr%#ti#& r+( !it$+t %(. #$%(&

L%stl., t$& &%r r%ti $%s )&&( #%l#+l%t&" %(" !ill )& $i$&r #-p%r&" t l%st .&%r>s

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4 Suse0sio0

4.1 I0troductio0

The suspension of a high performance vehicle is argua"ly one of the

most crucial systems to the vehicles overall performance% A motor+s po$er

can only matter if it can "e properly transferre! to the groun! through the

tires% The suspension maintains contact "et$een the tires an! the groun!*

$hich assures "oth sta"ility an! control of the vehicle :8;% &ne of the most

crucial moments that tire contact comes into play is $hen cornering%


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ro! mounting to the upper control arm* so as the $heel travels up it pulls on

the roc.er arm $hich e>ten!s the shoc.% A push ro! has the ro! mounte! to

the lo$er control arm* so as the $heel travels up the ro! pushes on the

roc.er arm $hich compresses the shoc.% For formula one applications* push

ro! is typically use! !ue to its ease of !esign% The push ro! !oes provi!e for

a slightly higher center of gravity* "ut $ith the ri!e height !esire! for these

vehicles* mounting a pull ro! system "ecomes a very complicate! an!

un!esira"le situation% A comparison of the layouts for push an! pull ro!

systems is sho$n "elo$%


For the 2015 Formula SAE car* the push ro! system from last year+s

car $ill "e carrie! over* as the nose of the car !i! not change !rastically an!

it provi!e! the "est possi"le layout% The rear suspension this year $ill "e

change! to a push ro! system as oppose! to the pull ro! from last year% The

pull ro! system not only !i! not provi!e enough $heel travel* "ut the pull

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ro! also "oun! up on the roc.er arm $hen in re"oun!% To eliminate this

pro"lem an! pro!uce the !esire! geometry* a push ro! system $ill "e

implemente!% This ne$ system $ill allo$ the $heels to maintain contact

$ith the trac. surface "etter* therefore improving traction%

4.2 *ethods

A s.etch $as create! in Soli!or.s to !etermine the control arm

geometry nee!e! to achieve a specific roll center $ith a given ri!e height%

A calculator create! "y the 2013 team $as then use! to !etermine the

static cam"er an! cam"er gain associate! $ith this geometry%

Figure 3? Suspension


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the &' machine shop an! $el!e! to the en!s of the control arms% These

allo$ for the iem -oints to "e threa!e! into the control arms* $hich allo$

the lengths to "e a!-uste! as nee!e!% Frame mounts for the control arms

$ere machine! an! "olte! to the frame% The control arms an! uprights $ere

moc.e! up $ith last year+s $heels so that the ri!e height for the car coul! "e

set% Suspension roc.ers for the front an! rear push ro! systems $ere

!esigne! in Soli!or.s an! machine! from aluminum%

Fi+r& 4< R#'&r M"&l

The roc.ers $ere moc.e! up on the frame $ith the shoc.s to verify the

mounting point* $here ta"s $ere then $el!e! to the frame% ith the ri!e

height set properly an! the roc.er arms in place* measurements $ere then

ta.en to con,rm the length of the push ro!s themselves% Tu"ing $as then

cut an! ro! en!s $ere $el!e! to each en! for iem installation% The car $as

then place! on its o$n $eight for the ,rst time to ensure that the suspension

components functione! as !esire!% oa! $as applie! to the front an! rear of

the car in!ivi!ually to ensure that proper -ounce an! re"oun! coul! "e

achieve!%

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4.# Resuts

The 2015 Formula SAE car+s suspension system provi!e! the !esire!

$heel travel $hile eliminating issues e>perience! in the previous year+s car%

The front push ro! system ha! a motion ratio of 2%3?1 $hich provi!e! 2%5

inches of -ounce $ith 0%5 inches of re"oun!% This system $as carrie! over from

the num"er 79 car* so there $ere no clearance issues as the !esign ha!

alrea!y "een teste!% The rear push ro! system ha! a motion ratio of 1%13

$hich pro!uce! 2 inches of -ounce an! 1 inch of re"oun!% &nly a minimal ratio

$as nee!e!* as the push ro! an! shoc. $ere .ept in plane $ith each other*

$hich pro!uce! an i!eal geometry% This !esign also eliminate! the "in!ing

issue e>perience! $ith the previous !esign* $hich ensure! a smooth range of

travel for the rear $heels%

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" Br/3es

".1 I0troductio0

T$& )r%'i( s.st&- is !$%t &(%)l&s % #%r t s%=&l. r&"+#& sp&&" %(" -%i(t%i( #(trl

A##r"i( t FSAE r+l&s, %ll =+r !$&&ls -+st +("&r )r%'i( =r#& !$il& pr&ss+r& is %ppli&"

t t$& )r%'& p&"%l Als, t$& )r%'&s -+st )& %)l& t l#' %ll =+r !$&&ls %t t$& s%-& ti-& I(

pr&/i+s .&%rs, t$& Ol" D-i(i( 6(i/&rsit. #%r $%" % "is# )r%'& ( &%#$ =r(t !$&&l %(" (&

"is# )r%'& ( t$& ri$t r&%r %l& %#ti( %s % r&%r #--( )r%'& +si( t$& "i==&r&(ti%l t %ppl.

)r%'& =r#& t )t$ r&%r !$&&ls $il& t$is s.st&- !r's, t$& r&%r )r%'&s $%/& l&ss )r%'i( =r#&

%/%il%)l& t$%( t$& =r(tB %(" !$&( t$& )r%'&s %r& %ppli&" t$& =r#& is +(&/&( )&t!&&( t$& r&%r

!$&&ls "+& t -$%(i#%l lss&s )&t!&&( t$& ri$t %(" l&=t %l&s t$r+$ t$& "i==&r&(ti%l 5 T

i-pr/& t$is .&%r>s #%r, t$& t&%- $%s "i"&" t +tili& % =+r !$&&l "is# )r%'& s.st&-

A(t$&r p%rt = t$& FSAE r+l&)' r&%r"i( )r%'&s is r&+iri( t! #-pl&t&l. s&p%r%t&

$."r%+li# s.st&-s T$& -&t$" +s&" ). t$& 6(i/&rsit.>s =r-&r t&%-s $%s )&&( t r+( t! )r%'&

-%st&r #.li("&rs, (& t #(trl t$& =r(t )r%'&s %(" t$& t$&r t #(trl t$& r&%r )r%'& T$is

.&%r>s s.st&- is si-il%r, )+t i( %( &==rt t i-pr/& +p( t$& l" "&si( %(" %##+(t =r

i(#r&%s&" r&%r )r%'i( =r#&, % )r%'& prprti(i( /%l/& $%s )&&( %""&" t t$& r&%r $."r%+li#

s.st&- T$& /%l/& !ill %ll! =r %"+sti( t$& "i==&r&(#& i( )r%'i( =r#& )&t!&&( t$& =r(t %("

r&%r )r%'&s At =+ll p&(, t$& =r(tHr&%r )r%'& )i%s !ill )& 5050 As t$& /%l/& is t+r(&",

r&"+#&" pr&ss+r& is i/&( t t$& r&%r )r%'&sB !it$ %"+st-&(t, t$& )r%'& )i%s #%( )& s&t t %(.

#-)i(%ti( "&sir&"

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".2 *ethods

C$%(i( =r- % si(l& r&%r "is# t "+%l r&%r "is#s $%s pr/i"&" %( &/&( )r%'i(

"istri)+ti( =r- l&=t t ri$t, t$+s i/i( t$& "ri/&r -r& #(trl !$&( t$& )r%'&s %r& %ppli&"

: T$&r& !&r& "&si( #$%ll&(&s t$%t $%" t )& /&r#-& !$&( %""i( i("i/i"+%l r&%r )r%'&s

T$& )i&st #$%ll&(& !%s #r&%ti( % li$t!&i$t, $i$ str&(t$, %(" #-p%#t -+(ti( s&t+p =r

t$& r&%r #%lip&rs %(" "is#s i()%r" = &%#$ !$&&l First, #%l#+l%ti(s !&r& p&r=r-&" t &st%)lis$

$! -+#$ )r%'i( =r#& !%s (&&"&" t l#' %ll =+r !$&&ls, !$i#$ is t$& -st t$%t t$& s.st&-

#+l" &(#+(t&r 8 T$&( %ll t$& p%rts !&r& "&si(&" =r t$%t =r#& -+ltipli&" ). % =%#tr =

s%=&t. A=t&r -+ltipl& pssi)l& )r%#'&ts !&r& "&si(&" i( Sli"r's, =i(it& &l&-&(t %(%l.sis

!%s p&r=r-&" %(" t$& )&st "&si( !%s #$s&( ?Fi+r& :@ T$& r&%r )r%'& "is# #%rri&r is % -+#$

-r& #-pl& "&si( T$& !$&&l #&(t&rs " (t $%/& t$& $l&s t %ll! )r%'& "is#s t -+(t

"irtl. t t$& !$&&l, s t$& r&%r rtr #%rri&r +s&s t$& spli(&s ( t$& $%l= s$%=ts t %ppl. t$&

)r%'i( =r#& =r- t$& rtr D t -%#$i(i( li-it%ti(s, it !%s i-pssi)l& t -illHl%t$& % (&

pi& rtr #%rri&r si-il%r t t$& =r(t rtr #%rri&r I( r"&r t pr#&&", =i(it& &l&-&(t %(%l.sis

!%s "(& +si( Sli"r's t #$' i= % t!pi&, !&l"&" rtr #%rri&r "&si( !+l" !r'B it

"i" ?Fi+r& 8@ T$&( t$& -%i( "is# sti( = t$& rtr #%rri&r !%s -%#$i(&" t =it % p+r#$%s&"

spli(& #ll%r i( t$& #&(t&r, %(" t$& t! pi&s !&r& !&l"&" t&t$&r %(" -%#$i(&" t $%/&

p&r=tl. p%r%ll&l =%#&s T$is %ll!&" t$& t&%- t $%/& % #-pl& pi& !it$+t #-pl&

-%#$i(i(

".# Resuts

Al-st %ll = t$& )r%'& #-p(&(ts "&si(&" %(" -%(+=%#t+r&" ). t$& t&%- !&r&

s+##&ss=+l i( =+l=illi( t$&ir rl&s T$&r& !%s % pr)l&- !it$ t$& r&%r )r%'& %(" !$&&l s&t+p, %

si(i=i#%(t !))l& i( t$& !$&&l %(" )r%'& +p( ti$t&(i( t$& %l& #-p(&(ts ( )t$ t$& l&=t

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%(" ri$t si"&s T$& #%+s& !%s =+(" t )& =%+lt. -%#$i(i( ( t$& )r%'& rtr #%rri&rB t$& =%#&s

= t$& #%rri&r t$%t -&t !it$ t$& !$&&l %(" )&%ri( sp%#&r !&r& (t p%r%ll&l, s (#& &/&r.t$i(

!%s ti$t t$& !$&&l %(" )r%'& rtr !&r& p+s$&" +t = %li(-&(t T$is !%s =i&" ). -illi( t$&

=%#&s p%r%ll&l t t$& rtr s+r=%#& ( t$& #%rri&r Si(#& t$&( ( pr)l&-s $%/& %pp&%r&" i( t$&

)r%'&s

D+ri( &p&ri-&(t%ti( =r t$& =r(t t r&%r )r%'& )i%s, t$&r& !&r& % #+pl& =

r&/&l%ti(s T$& &tr&-&l. r&%r $&%/. (%t+r& = t$& #%r -&%(t t$%t &/&( "+ri( )r%'i( t$& r&%r

= t$& #%r still $%" % si(i=i#%(t %-+(t = !&i$t ( it, s t$& =r(t $%" t $%/& l&ss )i%s t$%(

!%s pr&/i+sl. t$+$t ?#ls&r t 5050@ It !%s r&%li&" t$%t i= t$& r&%r !$&&l l#'&" %(" t$&

#l+t#$ p&"%l !%s (t "&pr&ss&", t$& &(i(& !+l" i--&"i%t&l. st%ll "+& t t$& #r%('s$%=t (t

)&i( %)l& t rt%t& T$& i(iti%l pl%( !%s t -%'& t$& r&%r !$&&ls l#' =irst i( r"&r t -%i(t%i(

st&&ri( %)ilit. i( % t+r(, )+t si(#& t$%t !+l" -&%( s$+tti( == t$& &(i(& t$& i"&% !%s

&li-i(%t&" %s % pssi)ilit.

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' I0t/3e

'.1 I0troductio0

T$& -%r #-p(&(ts = t$& i(t%'& %r& t$& r+((&rs %(" t$& pl&(+- A"+sti( r+((&r

l&(t$ #$%(&s !$&( p&%' t+& ##+rs i( t$& &(i(&s p&r%ti( r%(& T$& pl&(+- s+ppli&s

&%#$ r+((&r !it$ =r&s$ %ir %(" i(s t$&- %ll t t$& t$rttl& )". T$& 2014 OD6 FSAE #%r $%" %

#(& st.l& i(t%'& pl&(+- %(" l( r+((&rs !it$ s&/&r%l )&("s Prir t&%- -&-)&rs (t&" t$%t t$&

/&r%ll pl&(+- /l+-& !%s t s-%ll =r s+st%i(&" $i$ &(i(& sp&&"s, i( r&/l+ti(s p&r -i(+t&

?RPM@ I( %""iti(, t$& l( r+((&rs s$i=t&" p&%' p!&r l!&r i( t$& RPM r%(& %(" %!%. =r-

t$& "&sir&" r%(& = p&r%ti(, %)+t 9,000 t 12,000 RPM, #%+si( p!&r t =%ll == )&=r&

s$i=ti( T$& pri-%r. "&si( #rit&ri% =r t$& 2015 i(t%'& !&r& r+((&r l&(t$s pti-i&" =r

s+st%i(&" $i$ RPM "ri/i( %(" % l%r& pl&(+- /l+-& t s+pprt t$& =l! "&-%("s %t p&%'

+tp+t

'.2 *ethods /0d Resuts

$&( &(&r%ti( t$& i(iti%l "&si( #(#&pts, t! -%t&ri%l #$i#&s !&r& #(si"&r&" =r t$&

#(str+#ti( = t$& i(t%'&, #%r)( =i)&r %(" %l+-i(+- *t$ ==&r&" t$& )&(&=it = )&i(

li$t!&i$t, )+t &%#$ pr&s&(t&" "isti(#t %"/%(t%&s /&r t$& t$&r T$& -%i( %"/%(t%& = #%r)(

=i)&r !%s t$& %)ilit. t -%(+=%#t+r& #-pl& s!&&pi( s$%p&s, !$il& %l+-i(+- !%s % l! #st

pti( t$%t !+l" )& &%si&r t -%(+=%#t+r& !it$ Al+-i(+- !%s #$s&( =r s&/&r%l '&. r&%s(ss "r% %(" li=t T$&. %ls s&r/& %s !%. t

i(#r&%s& t$& rip )&t!&&( tir&s %(" r%" ). #r&%ti( % "!(=r#& Opti-ii( "r%, li=t, %("

"!(=r#& !ill i(#r&%s& % /&$i#l&s %##&l&r%ti( !$il& -%i(t%i( (&ss%r. rip T$& #-p(&(ts

+s&" ( t$& 20142015 OD6 FSAE #%r !ill )& % (s& #(&, si"& p"s, %(" % r&%r %#ti/& "i==+s&r

%.2 *ethods

A Sli"r's -"&l = t$& r&%r "i==+s&r, si"& p"s, %(" (s& #(& $%/& )&&( #r&%t&" A

2D C-p+t%ti(%l Fl+i" D.(%-i#s ?CFD@ = t$& si"& p" %(" "i==+s&r !%s #("+#t&" t /&ri=.

t$& #r&%ti( = % l! pr&ss+r& %r&% +("&r t$& #%r T$is pr/&s t$& "i==+s&r #r&%t&s % "!(=r#& ).

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$%/i( % $i$ pr&ss+r& ( tp %(" l! pr&ss+r& +("&r(&%t$


T$& "i==+s&r !%s -%"& !it$ % 25 r%-p T$is %(l& is st&&p &(+$ t -%i-i& t$& l! pr&ss+r&

%r&% +("&r t$& /&$i#l& !$il& (t )&i( t st&&p t$%t it #r&%t&s t+r)+l&(#& 10 T$& si"& p"s $%"

t )& !it$i( t$& !$&&l )%s& )+t l%r& &(+$ t =it t$& /&$i#l&s #li( s.st&- 11 T$& (s&

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#(& "&s r&"+#& "r% )+t its -%i( p+rps& is t $+s& %( i-p%#t =r#& r&"+#ti( "&/i#& i( #%s&

= % #r%s$

Ml"s = t$& %&r".(%-i# #-p(&(ts !&r& )+ilt i( r"&r t %ppl. t$& )". -%t&ri%l A

)i%i%l 4545 18 =i)&rl%ss !%s #$s&( i( r"&r t st%. !it$i( t$& "&=lti( tl&r%(#& st%t&"

i( t$& FSAE +i"&li(&s

%.# Resuts

Sli"r's !%s +(%)l& t pr/i"& =+ll 3D CFD %(%l.sis "+& t %/%il%)l& r%- ( %

p&rs(%l #-p+t&r Sli"r's =il&s $%/& t )& #(/&rt&" t COMSOL ?COMSOL Gr+p,

St#'$l- S!&"&(@ "+& t t$& Li(+ p&r%ti( s.st&-s OD6>s s+p&r#-p+t&r +s&s O(#& t$&

=il&s %r& #(/&rt&", t$& #&==i#i&(ts = li=t %(" "r% #%( )& #%l#+l%t&" %l( !it$ "!(=r#&

#r&%t&" ). t$& "i==+s&r

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+ iscussio0

T$& p+rps& = +r prt !%s t "&si( %(" =%)ri#%t& % Fr-+l% SAE #%r t$%t #%(

&&" t$& p&r=r-%(#& = l%st .&%r>s #%r %t t$& Fr-+l% SAE #-p&titi( i( M%., 2015 it$

t$& =#+s ( pti-ii( t$& s+sp&(si(, "ri/&tr%i(, %(" i(t%'&, +tp&r=r-i( t$& 20132014

t&%- #%( )& %##-plis$&"

Mst = t$& t&%->s r&s+lts #%-& =r- (li(& r&s&%r#$ %(" #-p+t%ti(%l %(%l.sis = &%#$

-%r #-p(&(t = t$& #%r As t$& #%r>s =%)ri#%ti( is )&i( #-pl&t&", t&sti( !ill #--&(#&

i( t$& (&%r =+t+r& T$& &(i(& !ill )& r+( t$r+$ % ".(%--&t&r t -&%s+r& t$& tr+& %("

p!&r = t$& &(i(& T$& "ri/&tr%i( t&sti( !ill ##+r !$&( t$& #%r is "ri/&( t "&t&r-i(& i= t$&

&%r r%ti s&lt&" is pti-%l =r #-p&titi( L%stl., t$& "ri/&r #(trl #-p(&(ts !ill )& t&st&"

"+ri( tr%#' pr%#ti#& t #(=ir- t$%t pti-%l "&si(s $%/& )&&( s&lt&"

Cr&%ti( % -r& &==i#i&(t r&%r s+sp&(si( s.st&- !ill i-pr/& t$& #(trl = t$& #%r

it$ % )&tt&r s+sp&(si( "&si( t$& #%r $%s s-t$&r !&i$t tr%(s=&r %(" #%( $%("l& i( #r(&rs

)&tt&r R&s&%r#$i( s+sp&(si( &-&tri&s %(" "&si(i( t$&- t$r+$ #-p+t%ti(%l t&sti(

$&lp&" t$& t&%- "&t&r-i(& !$i#$ s+sp&(si( "&si( !%s t$& )&st T$& r&s+lts #-i( =r-

si-+l%ti( t&sti( =i(%li&" t$& r&%r s+sp&(si( "&si( %(" %ll!&" =r =%)ri#%ti(

T$& "ri/&tr%i( is i-prt%(t =r t$& &("+r%(#& prti( = #-p&titi( T$& &%r r%ti !%s

%"+st&" s t$%t t$& #%r !ill )& #%p%)l& = s$i=ti( t$r+$ %ll &%rs "+ri( t$& &("+r%(#&

#-p&titi( 6si( r&s&%r#$ %(" "is#+ssi(, % )&tt&r &%r r%ti !%s s&lt&" =r t$is .&%r>s #%r

T %#$i&/& -r& &(i(& p!&r t$& i(t%'& !%s r&"&si(&" T$& %"+st-&(t = t$& r+((&r

l&(t$s !+l" %==t !$&( p&%' tr+& is %#$i&/&" Als r&str+#t+ri( t$& pl&(+- =r- l%st

.&%r>s #%r &+%li&" i(t&r(%l pr&ss+r& =r -r& &/&( "istri)+ti( = %ir t t$& &(i(& %(" $&lps

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#r&%t& -r& &==i#i&(t #-)+sti( i( t$& &(i(& T$& /&r%ll "&si( = t$& i(t%'& s.st&-

"&t&r-i(&s &(i(& p!&r, s pti-%l "&si( !%s '&.

T$&r& !&r& % =&! li-it%ti(s t t$& prt t$is .&%r, )+t t$& li-it%ti(s "i" -%'& %(

i-p%#t ( "&l%.i( t$& prr&ssi( = t$& prt O(& li-it%ti( t$& t&%- =%#&" !%s t$& l%#' =

Sli"r's "&si( '(!l&"& Mst -&-)&rs = t$& t&%- $%" littl& r ( Sli"r's

'(!l&"& A(t$&r '&. li-it%ti( t$& t&%- =%#&" !%s t$& i(%)ilit. t !&l" i( t$& -trsprts

l%) it$+t t$& %)ilit. t !&l" ( sit& t$is sl!&" prr&ss = t$& #%r>s =%)ri#%ti(, #r&%ti( %

"&l%. i( =i(%lii( t$& prt T$is li-it%ti( !%s /&r#-& ). s&%r#$i( =r t$&r l#%ti(s t

!&l" !$il& !& !%iti( =r $t !r' p&r-its t #-& i( T$%('s t t$& #p&r%ti( = t$&r

p&pl& +tsi"& = t$& l%), s+#$ %s t$& OD6 -%#$i(& s$p, t$& !&l"i( !%s %)l& t )& -%"& +p t

&(s+r& #-pl&ti( = t$& prt )&=r& #-p&titi(

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Re6ere0ces

:1; S% Beller* C/D? 'rivetrain Stu!y ui!e* /elior Gnc%* pp 3#* 2007%

:2;


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Ae0dices

Ae0di7 A8 ,/0tt Ch/rt

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Ae0di7 B8 Bud9eted :ours /0d Pro9ressio0

12N27N201 2N15N2015 N6N2015 5N26N20150

100

200

300

00

500

600

&' Formula SAE or. ours

Average u!gete! ours

Theorectical Average

u!gete! ours

ee.s

ours

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Ae0di7 C8 Bud9et

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3


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Ae0di7 8 Fi9ures



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Fi+r& 3< S+sp&(si( C%l#+l%tr

Fi+r& 4< R#'&r M"&l

Fi+r& 5< R#'&r CAD "r%!i(

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Fi+r& :< Fr(t C%lip&r *r%#'&t

0


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Fi+r& 8< Fr(t Rtr C%rri&r

1


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Fi+r& 9< R&%r C%lip&r *r%#'&t

2


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Fi+r& ;< R&%r Rtr C%rri&r

Fi+r& 10< R&%r *r%'& Ass&-)l. I()%r"

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Fi+r& 11< I(t%'& M"&l

Fi+r& 12< F+ll i(t%'& =l! %(%l.sis

Fi+r& 13< T$rttl& )". =l! %(%l.sis


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Ae0di7 E8 E;u/tio0s

(( rpmoverallgear ratio)(60min ))/(5280 feet)

E+%ti( 1< G&%r R%ti E+%ti(

RPM=81c A(R1 )LV(R+1 )

# K l#%l sp&&" = s+(" ?=tHs@

A K #rsssti(%l %r&% = i(t%'& r+((&r ?i(2@

L K r+((&r l&(t$ ?i(@

K #.li("&r "i&pl%#&-&(t ?i(3@

R K #-pr&ssi( r%ti ?"i-&(si(l&ss@

E+%ti( 2< R+((&r L&(t$ E+%ti(

finalpaper - copy

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