Project Aspect 3 (Engine Cooling) The cooling system is responsible for preventing the engine from overheating. The system involves a radiator, fan, and coolant. Final Product: Path Forward: Detailed designs for radiator are ducting will allow for composites manufacturing over Winter Session 2011. Electric fan will be permanently mounted on the back of the composite ducting. The entire cooling assembly will be bolted to the right side of the chassis as shown in the figure.

Project Aspect 2 (Air System): Intake and Exhaust The car’s air system is made up of an intake and exhaust. The intake supplies air to the engine, which mixes with fuel to be combusted inside the engine. It is made up of a throttle body, restrictor, plenum, runner, and fuel injector. The exhaust is made up of a muffler, and main tube. It is responsible for carrying away the gases produced inside the engine’s combustion chamber. Metrics (Intake): Final Product: Path Forward: Intake - Will be used to determine optimal plenum and runner sizes based on hp and torque compared to RPM leading to final intake design and manufacturing. Exhaust - The stainless steel exhaust prototype will be used for testing to ensure proper noise requirements are met on the 2010-2011 engine, while optimizing power made from proper exhaust length.

Project Aspect 1 (Drivetrain): Hubs Primary Objectives: • Hold the wheels to the vehicle via 4 lug bolts • Allow wheels to rotate via press fit into wheel bearing • Allow the engines torque to be transferred to the wheels via internal splined interface with axles Geometric Constraints: FEA Validation: Examine worst case static stress resting, acceleration, braking, and cornering scenarios. Lowest factor of safety = 2.6. Worst case fatigue scenario yields fatigue failure after 28hrs of use. Minimal Cost: $130 Minimal Weight: 3.1lb each Final Product: Path Forward: The rear hubs will be heat-treated and broached (internal splines) at RCV Performance over Winter Session 2011. Lug bolts and wheel bearings will be pressed in place. The upright assemblies will be completed with components from suspension. The completed hubs will be installed on the new car and put under dynamic vehicle testing.

Project Aspect 1 (Drivetrain): Axles The rear axles are responsible for transmitting the engine’s power (through torque) to the wheels. The design concept selected for the axles was a modified main shaft. Two Honda TRX350 rear axles were cut, then press fit into different length 4130 Chromoly Tubes to meet required vehicle track targets and perform under maximum torque requirements. Experimental Testing- Test axles were loaded through an Instron machine to find maximum allowable torque.

UD Senior Design Team FSAE Powertrain Michael Honeychuck, William “Jay” Kistler, Nicholas Piacente, Adam Stager

Faculty Advisor: Dr. Steve Timmins

Sponsor: Paul Schwarz (Main Line Porsche of Newtown Square)

Acknowledgements We would like to thank our sponsor, Mr. Paul Schwarz, and our advisor Dr. Steve Timmins for their advice and expertise. Also, a personal thanks to the employees at RCV Performance Products, PowerSports East, Martelli’s Metal Fabrication, Inc., Adam Kinzey and Doug Brunner, Steve Beard and CMX Machining.

FSAE Background Each year since 1979, SAE International hosts an collegiate automotive design competition called Formula SAE. Participating schools must design and develop a small Formula-style race car to be judged and competed against cars from other schools. FSAE cars have engine displacements less than 600cc, have a 20-mm restrictor on their intake systems, and typically weigh less than 600 lbs. The University of Delaware has been a competing member since 1996, but has never actually completed all of the events.

Project Scope As the Powertrain team, we were responsible for all major support systems for the engine: air, final drive, and cooling. More specifically, final project deliverables will include rear axles, rear wheel hubs, prototyped air intake, exhaust manifold, radiator and fan.

Project Aspect 1—Drivetrain

Rear Hub

Rear Axle Differential

Rear Hub Rear Axle

Project Aspect 1 (Drivetrain): Differential The differential is the mechanism that allows the rear wheels to travel at different speeds. This aspect of the project involved selecting a differential and developing a housing. Final Product: Path Forward: The differential assembly is ready for testing and permanent mounting onto the chassis. The housing will be bolted onto the chassis’ mounting tabs. Axles will be pressed into the differential and locked with the c-clips on the ends of the axle shafts.

Metric Target Value Old New Savings

Cost <$600 $628 $534 $94.00 (14%)

Weight <7 lbs 7.75 lbs 6.10 lbs 1.65 lbs (21%)

Total Assembly Length <10 inches 10.25 inches 4.96 inches 5.29 inches (51%)

Durability No Leakage Minor

Leakage Not fully Tested

---

Metric Target Value

Old New (Left Axle)

New (Right Axle)

Savings

Cost <$1,000 team $1,775.60 $122.47 $122.47 $1,530.66

Weight <6.9 lbs 6.9 lbs 6.3 lbs 6.9 lbs 0.6 lbs

Deflection at 20 ft-lbs

<0.68 degrees 0.68

degrees 0.61

degrees 0.82

degrees Insignifigant

Allowable Torque

165 ft-lbs --- 335 ft-

lbs 335 ft-

lbs ---

Metric Target Value Old New Savings

Cost <$15 unknown $9 ---

Total Weight <5 lbs 4.75 lbs 4.25 lbs 0.5 lbs (12%)

Volume Space < 1,872 cubic inches

(8”x13”x18”) 500 cubic inches

(10”x10”x5”) 1,465 cubic inches

(7.4”x11”x18”) none

Heat Dissipated >17,000 W 16,861 W 20,753 W 3,892 W

(23%)

09-10 Car New Prototype

Air Filtration Area 17.69in2 43.24in2

Plenum Volume 2.5*511cc [2.5*511cc:5*511cc]

Runner Length 13.3in [11.3in:17.3in]