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?