Rolling Chassis Team

Todd AndersonMatt BlackwoodDavid Hovater

Josh SmithJessica Yoho

Overview

Formula SAE at a Glance Project Summary

Frame Suspension Brakes Steering Seat Uprights

Building Parts Lathe Mill Large Band Saw Small Band Saw Composites

Important Dates

Formula SAE Competition

One of the largest Collegiate competitions Design, build, and compete with small Formula style cars 140 Universities from around the world compete in static and

dynamic events Increase awareness for The University of Alabama Covers many aspects of Engineering Competition Date: 5/18/2005 – 5/22/2005

Formula SAE

0-60 in under 4 seconds Can corner up to 1.5 g’s Weighs around 500lbs 70 Hp Engine

Project Statement

Design, build, and test a rolling chassis for integration with the 2005 UA Formula SAE car design.

2005 Car at a Glance

2005 Car at a Glance

66” Wheelbase 48/46” Front Rear Track Seating Position under the Main Roll Hoop Two Pedals Pull Rod Suspension Semi Stressed Engine

Frame at a Glance

Frame Objectives

Reduce Weight Less than 60lbs total weight for the Frame Use of Thinner Tubing

Increased Driver Room Increase Torsional Resistance Reduce Complexity

Integrate Subsystems into Frame Use of Square Tubing Partially Stressed Engine Easier to Build

4130 Spaceframe

Frame Analysis (Front)

FEA Analysis in ANSYS Max Deflection: <0.08in Max Stress <31ksi

Suspension at a Glance

Double A-arms Low Roll Center Pull Rod Vanilla RC

Bicycle Shocks Anti-Sway Bar Use of Spherical

Bearings

A-arm Attachment to Frame

Shims

1/4” bolt

Aluminum Bracket

Spherical bearing & housing

A-arm

Front View

Spherical Bearings

Mis-Alignment Angle of 24º Will Be in Housing held in place by a

snap ring

Front A-arms Analysis FEA ANSYS Results

Loaded to Simulate Braking and Cornering Max Deflection <0.05” Max Stress <22ksi

Brakes At a Glance

3 Disc Setup 2 Outboard Brakes in Front 1 Inboard in Rear

9” Diameter Rotors Dual Piston Calipers Left Foot Brake setup (Only two Pedals) Balancing Bar

Brakes

Wilwood PS-1 Calipers Dual 1.12 inch pistons

9”Custom Rotors Dual master cylinders

Balancing bar used to adjust bias

PS-1 Caliper

Dual MC

Balance bar

Steering

Located under Driver’s legs Ackerman Geometry 12 ft Turning Radius Minimal Bump Steer Two Universal Joints to Route Steering

Linkage

Steering Rack

•Track Travel: 3”

•Weighs 1.96 lbs

•Rack Length is 8.5”

•1.125 Turns Lock to Lock

Jr. Dragster Steering Rack From Chassis Shop

Seat at a Glance

Carbon Kevlar Composite

Reclined 30º from the Vertical

Legs Elevated 4” Lateral Support

Front Uprights

Front Upright

Brake Caliper Bracket moved to integrate into Steering Attachment

Steel Construction opposed to Aluminum Similar Weight Reduced Cost Easier to Make Endurance

Rotor Mount integrated into Wheel Studs Smaller Spindle and Inboard Bearing to take

Advantage of Strength of Steel

Front Upright FEA Analysis

ANSYS Max Deflection

<0.003” Max Stress < 16ksi

Weighs Approximately 2.75lb with Axle and Brake Bracket

Rear Uprights at a Glance

Aluminum 6061-T6 CNC Design Minimal Deflection Lightweight Taylor Racing Stub Axle

Rear Uprights Overall Dimensions Constraints / Loading Conditions Maximum Deflection is 0.002” Maximum Stress is 3500 psi

Stub Axle

Stub Axle Assembly will be changed to same model used in 2004 Car More Expensive but can be covered with

new Funds Much Stronger, more Proven, and Lighter Manufactured by Taylor Racing

Building Plans

Construction of Rolling Chassis needs to be completed by December 16th

489 Currently occupying Projects Building

Starting November 11th 1-4pm Weekday Afternoons

Wednesday November 24th – All day

Lathe

Spindle Housings for Spherical Bearings Engine Mounts

Mill

Frame Members Pieces for Jig Table Assembly Jig for Front Upright A-arms Brake Rotor

Large Band Saw

Frame Members Front Upright Pieces A-arms

Small Band Saw

A-arm Attachments Front Upright

TIG Welder

Frame Frame Jig Table Front Uprights A-arms A-arm mounts to

Frame

Other

Bench Grinder A-arm Attachments Front Upright

Chop Saw Frame Members

Composite

After

Step 1: Sand seat to proper dimensions

Step 2: Apply Bondo to the entire seat Let seat dry for 24 hours

Step 3: Sand down seat to a smooth finish with fine grit sandpaper

Step 4: Cut several sheets of Carbon Kevlar fabric to the specified dimensions.

Step 5: Lay one sheet of fabric vertically on the seat mold and apply resin. Allow to dry.

Step 6: Lay another sheet of fabric horizontally on the seat mold and apply resin. Allow to dry. Repeat as needed.

Step 7: Discard foam mold.

Before

Important Dates

November: 7th Last Autocross of the year in Birmingham 17th Engine Mounted to Dyno 24th

Drivetrain Coupling Completed Composite Process Build Date in Projects Building

December: 4th Stock Engine Running 16th Rolling Chassis Completed

January: 21st

Running Engine With Restrictor Pedal Construction

March: 18th

Driving

Questions?