Sheffield Hallam University

Formula Student

Virtual Lecture by

R Harris MSc, BEng, CEng, MIET

Lecture Objectives• To understand the design of vehicle to

meet a particular specification; Formula Student

• To examine the design process

• To understand the engineering decisions made

• To review the final product

What is Formula Student ?

" While ostensibly about the design and production of a single-seater racing car, Formula Student is actually more about building future engineering talent, not just in design and manufacture, but in many of the management, marketing and people skills so vital in the modern world, across all sectors of employment. "

Institution of Mechanical Engineerswww.imeche.org

How does it relate to Formula SAE* ?

• A British version of Formula SAE using the same rules.

• There are also similar events in Italy, Brazil, Australia.

*Society of Automotive Engineers

Basic Rules• The design must conform to the 119 page SAE rule

book• A completely new car must be built every two years• "Vehicles entered into Formula SAE competitions

must be conceived, designed, fabricated and maintained by the student team members without direct involvement from professional engineers, automotive engineers, racers, machinists or related professionals."

Basic Design

• Open cockpit• Must have 4 wheels• Brakes must operate on all 4 wheels• Max 610cc engine• Super or turbo charging permitted• Must have roll hoops for driver safety• Monocoque and space frame acceptable• Seat harness mandatory

Typical Designs

The next slides give examples of vehicles that have previously been constructed

India – Delhi College of Engineering,

Canada – University of Toronto

Sheffield Hallam’s Formula Student car

Key Design Decisions Needed• type of engine – petrol, diesel, no of

cylinders, turbo or supercharged, engine management

• drive train – shaft drive, chain drive, transmission type

• frame – monocoque or space frame

• frame material(s)

Design Constraints• physical resources - machine shops,

welding facilities, modelling software etc

• intellectual resources – student and staff experience and expertise

• students skill set

• time, people and finance available

• cost

Analysis of Spaceframe Design

Solid Model of Baseline Chassis

Driver Size Relative to Chassis

Does the Rollbar Meet the specificatioin?

Check with a Real Person

Suspension

Constraints:

• need to leave space for driver

• mounting points available on frame

• need to minimise weight of components

• need to used commercially available components

Front Suspension and SteeringAn initial Proposal

Front SuspensionAs implemented

Rear Suspension

Rear Suspension

Complete Chassis

Engine and Transmission

Constraints:

• physical size to fit frame

• capacity allowed

• expertise available

• finance available

• development time available

Decisions Made

• commercially available motorcycle engine

• use liquid cooling as more flexible

• normally aspirated due to limited time and expertise develop forced induction

• use existing engine management system initially

• optimise on dynamometer

• use existing gearbox

Issues to Resolve

• torque/speed characteristics need modifying to achieve low speed torque

• need additional cooling to cope with low air velocity

• gear selection

Dynamometer Engine Testing

Engine in Frame

Front Suspension and Steering

SHU Racing Team

• SHU Racing team students who work on the car have individual projects

• Matthew Ross is a current student

• He has kindly provided his presentation to show his project of improving the petrol tank for the car

MY PROFILE

MATTHEW ROSS

• 19 YEARS OLD• FROM LINCOLNSHIRE

• FIRST YEAR STUDENT AT SHEFFIELD HALLAM

• STUDYING COMPUTER AIDED DESIGN TECH

FUEL PUMPSUZUKI GSX MOTORBIKE

• FUEL FILTER• FUEL PRESSURE

REGULATOR• FUEL PUMP

UNIT MUST BE SUBMERGED

MUST REMAIN VERTICAL DURING OPERATION

PROBLEMS WITH OLD TANK

• DESIGNED FOR USE WITH PREVIOUS CAR

• PUMP COULD NOT BE SUBMERGED INSIDE TANK

• TANK WAS LOCATED NEAR EXHAUST MANIFOLD

• FUEL FILLER NECK WAS ILLEGAL (FIA / SAE RULES)

MUST ACCOMMODATE FUEL PUMP

MUST FIT INTO CHASSIS CAVITY

MUST HAVE SUFFICIENT CAPACITY

FILLER NECK MUST COMPLY WITH REGULATIONS

INTERNAL VOLUME CAN BE CALCULATED

MANUFACTURING PLANS CAN BE CREATED

INTERFERENCE FITS CAN BE IDENTIFIED

MUST ACCOMMODATE FUEL PUMP

MUST FIT INTO CHASSIS CAVITY

MUST HAVE SUFFICIENT CAPACITY

FILLER NECK MUST COMPLY WITH REGULATIONS

INTERNAL VOLUME CAN BE CALCULATED

MANUFACTURING PLANS CAN BE CREATED

INTERFERENCE FITS CAN BE IDENTIFIED

MIG WELDS ON NEW PETROL TANK

NEW PETROL TANK OFFERS:

20% WEIGHT REDUCTION

INCREASED CAPACITY FROM 4 TO 5 LITRES

Initial Design for the Electrical System

Circuit diagram

Body Work - Design Options

Bodywork designs and ideas

CAD drawings of body on frame

Profile Image of Car

Actual bodywork

Track testing

Initial Testing

At the Event

Each team car goes though rigorous testing process

• Static Events:Design, Cost & Presentation Judging - High scoring part of competitionTechnical & Safety ScrutineeringTilt TestBrake & Noise Test

• Dynamic EventsSkid Pan (Figure of 8)SprintAccelerationEndurance & Fuel Economy

Engine testing

Scruitneering

The Noise Test

Tilt test

The brake test

Practice

The BIG event!• Average speed should be 48 km/hr (29.8 mph)

to 57 km/hr (35.4 mph) with top speeds of approximately 105 km/hr (65.2 mph).

• The event will be run as a single heat approximately 22 km (13.66 miles) long. Teams are not allowed to work on their vehicles during the heat.

• A driver change must be made during a 3minute period at the mid point of the heat.

Starting grid

Video of the Race

The finishing line

On the podium

The team