Project Final Presentation P09221 – Innovative Composite Parts for a Formula SAE Racecar Tiago Santos (ME)

FSAE Racecar & Engine Intake Pipe

Project Status Innovative Composite Parts for a Formula SAE Racecar Project Name Innovative Composite Parts for a Formula SAE Racecar Project Number P09221 Project Family FSAE Autosports Track Vehicle Systems Technology Start Term 2008-1 End Term 2008-3 for MSD2 Faculty Guide Dr. Alan Nye (ME), Confirmed Faculty Consultant Dr. Hany Ghoneim (ME), Confirmed Primary Customer RIT Formula SAE team, Confirmed

Phase 1: Concept Development Identify Customer Needs - Interviews Primary Customer(s) Formula SAE team - the target market was identified after interviewing the project guide. Following interview with customer clearly provided the project’s scope and goals. At this point, it is known that the Formula SAE team needs three distinct composite parts to be produced and ready to mount on its competing racecar. Two sets of interviews have been accomplished with both guide and costumer. Other Stakeholder(s) As I am working closely with Dr. Ghoneim on a research this quarter, he has agreed to provide as much information about composite materials theory whenever needed. Past Senior Design Team(s) The Formula SAE team has provided several projects to senior design students for over 5 years. As some of the alumni were also team members, it will be possible to easily get in hold with them and arrange interviews with at least one past senior design team leader.

Phase 0: Planning Mission Statement Product Description /Project Overview This product is a structural composite component for a formula SAE racecar specifically designed to enhance its engine efficiency and track performance. The part proposed for the scope of the project is the engine intake pipe. Key Business Goals/Project Deliverables The primary business goals of this product are to This product has to yield a lighter and stiffer car able to achieve better records in several competitions which RIT’s Formula SAE team participates. The intake pipe has to increase the engine’s efficiency, enhancing the car’s overall performance and reducing fuel consumption. Development of manufacturing process which permits production in series of the part Primary Market /Project Opportunities The composite part is initially intended to serve solely the RIT Formula SAE team. The result of their design and manufacturing could raise the bar of Formula SAE competitions’ standards and expectations. In addition, they will help to elevate the visibility of RIT’s engineering programs as the improved car could achieve top performances. Secondary Market /Project Opportunities The improved car can attract potential students interested in mechanical engineering. It can promote the automotive option in the department and bring new recruits to the Formula SAE club. Stakeholders Formula SAE team Dr. Nye and Dr. Ghoneim Formula SAE events RIT Mechanical Engineering Department Sponsors Vendors Prospective Students Multi-Disciplinary Senior Design (MSD) RIT community in general

Phase 1: Concept Development Identify Customer Needs - Interpret Customer Needs Breakdown : 1.Performance 1.1 Increase engine power (9) 1.2 Lighter than current design (10) 1.3 Resonance optimization (7) 1.4 Optimize mass flow (9) 2. Structural Integrity 2.1 Withstand internal pressure (10) 2.2 Durable/ Long fatigue life (7) 3. Production 3.1 Development of cheap & fast production method (8) 3.2 Production in series (6) 4. Easy Maintenance (5)

Target Specifications Metric # Need # Metric Importance Units Marginal value Ideal Value 1 Need 1.1 Engine Power High HP >5% improvement >10% improvement 2 Need 1.2 Weight Lb <2.5 lbs <2.0 lbs 3 Need 1.3 Internal Resonance Medium Unitless Little effect Non-effect 4 Need 1.4 Mass flow Oz/s >0.20 oz/s >0.26 oz/s 5 Need 2.1 Internal Pressure (differential) Psi >11.6 psi >23.2 psi 6 Need 2.2 System Life Cycles >104 cycles >105 cycles 7 Need 3.1 Cost $/part <500 $ <300 $ 8 Need 3.2 Production Rate Parts/year 9 Need 4 Maintenance Low <200 $ <100 $

Staffing Requirements Name Discipline Role / Skills Dr. Alan Nye ME Faculty Guide. Will work closely with the team on an on-going basis to facilitate success. Also provides administrative support and funding acquisition. Dr. Hany Ghoneim Faculty Consultant. Will provide composite expertise, including Matlab code. Tiago Santos Team Leader. Will work closely with the team and the Faculty Guide on an on-going basis for the completion of this project. Is responsible for planning, organizing, and managing resources with updates to the EDGE website. Anthony Salvo Fluid Mechanics Concentration. Will be responsible for selecting the optimal intake pipe design. Will perform CFD analysis for the system. CFD analysis in ANSYS is highly recommended. Ryan Baldi Structural Composite Concentration. Will be responsible for selecting the appropriate composite material and fibers layout. Will perform stress analysis in both Matlab and ANSYS. Knowledge of finite element analysis for the system is highly recommended. Dave Holland Manufacturing Concentration. Will be responsible for selection of suitable composite production process. Technical experience in the field is highly recommended. TBD Student EE Will be responsible for designing data acquisition system for testing the part on the racecar. Will recommend appropriate gages to install on the part. Will perform installation of electrical components. Labview knowledge is recommended for prior system simulation.

Work Breakdown Structure Define Requirements Access Interactive Loads Create Software Model Run Simulation Define Specifications Evaluate Existing Products Determine Best Option Test Define Specifications Evaluate Existing Products & Techniques Determine Best Option Build Produce a Sample Build Machine & Finish Test Refine Part Install Gages & Controls Mount on car Test Test on Track

Preliminary Schedule MSD I

Preliminary Schedule MSD II

Resources Faculty Source Description Available Dr. Alan Nye ME Faculty Guide Yes Formula SAE team Customer Dr. Hany Ghoneim Technical Consultant Dave Hathaway Machine Shop Environment Source Description Available FSAE Room ME 09-2450 Work Space Yes Sr Design Lab ME 09-4xxx Pending ME Machine Shop ME 09-2360 Parts Fabrication

Resources Equipment Source Description Available Desktop PC with ANSYS and MATLAB ME Labs & FSAE room Calculations and Simulation Models Yes Power tools ME Machine Shop Parts Fabrication Tensile Test Machine ME Mechanics Lab Parts testing Materials Source Description Available Composite Fibers FSAE team Kevlar, Carbon and Glass Fibers YES Composite Resin Epoxy & Polyurethane Gages & Data Acquisition Device Mass flow & pressure gages. Data acquisition board. Yes, but might be necessary to purchase others.

Issues & Risks Description of Risk Possible Consequences Probability of Risk (H/M/L) Severity of Risk (H/M/L) Overall Risk (H/M/L) Contingency Plan There is a possibility of not being able to separate FSAE & Senior Design duties . Loosing of focus on the Senior Design Project. M H It is up to the project manager to make sure that such thing does not happen. If so, call the attention of the group. There is a possibility of the racecar not being ready for testing on time. One will not be able to test the part on the new designed racecar. Old FSAE racecar version will be used in place for testing. It will take more time to adapt our part on it. There is a possibility of not being able to find a EE student to perform the desired tasks The success of this project will depend heavily on the ability to acquire testing data of the mounted part on the track. It is important to have a good data acquisition system L The circuit itself, according to the ME staff, is trivial. With some effort the team will be able to cope without an EE.

Intellectual Property Considerations All work to be completed by students in this track is expected to be released to the public domain. Students, Faculty, Staff, and other participants in the project will be expected to release rights to their designs, documents, drawings, etc., to the public domain, so that others may freely build upon the results and findings without constraint.

Team Values & Norm Punctual Thorough Accurate Professional and Ethical Each team member will be prompt and arrive at the team meetings on time. If an unexpected conflict comes up, the absent team member will notify at least one team-mate prior to the expected absence. An absent team-member should confirm that a team-mate has received their message (in person, voice mail, email, etc). Thorough Each team member will complete their tasks thoroughly and completely, so that the work does not have to be re-done by a peer on the team. If a member does not know how to complete a task, feels overwhelmed, or needs assistance then the member notifies peers, and seeks assistance either from a peer, the faculty guide, a faculty consultant, or another person. Accurate Each team member completes their work accurately and in a way that can be easily checked for accuracy by peers and the faculty guide. All work is fully documented and easy to follow. Professional and Ethical Each team member gives credit where credit is due. All work completed includes citations to appropriate literature, or sources of assistance. If a team member has gotten assistance from a publication or individual, then that assistance or guidance is fully documented in the reports prepared. Each team member is honest and trustworthy in their dealings with their peers.

Grading and Assessment Scheme Grade Level MSD I MSD II D Students have failed to meet requirements. Schematic drawings for the engine intake pipe were not present or were insufficient. There was no progress on concept development including stress analysis and CFD. Edge website does not present enough documentation. Device does not meet requirements. It is not compatible with existing racecar nor exhibits any possibility for modifications which would yield compatibility. No testing data was presented. There is insufficient information to back the project out. Many documents missing on the Edge website. C Students have barely met requirements. Schematic drawings, CFD and stress analysis are present but not necessarily satisfy needs. Some documentation is present and exposed at the Edge website. Device meets some requirements. Data obtained from testing is meaningless. The device is still not perfectly functional to include in the racecar design. B Students met all requirements. The project lacks creativity or was limited to minimum requirements. All documents were provided and are available at Edge website. Device meets requirements and seems to be compatible with racecar. The data acquired from testing makes sense and meets expectations. However, the device could be further refined and interpretation of the data is mediocre. Documentation on Edge website was provided. A Excellent concept development work. Students went beyond the scope of the project. All requirements were fulfilled and documentation is complete at the Edge website. Device goes above any requirements or expectation. It can be incorporated in to following racecar design. It left a legacy behind. All Edge documents are well organized and present.

Future Plan Where do you go from here? Find more about budget Review Target Specifications - Confirm Staffing