P09221: Innovative Composite Parts for a Formula SAE Racecar Team Members: David Holland Theodore Kusnierz Anthony Salvo Ryan Baldi Charles Thomas Martin Iwanowicz

Primary Engineering Specifications Pedal Box 1.) Pedal load = 200lb 2.) Weight: < 1.5lb 3.) Deflection Magnitude: <.010” 4.) Accommodate driver heights between 5’5” and 6’5” Undertray 1.) Minimum clearance between chassis/suspension and tray: 1/32” 2.) Lift: 25mph 3.) Weight: < 25lb Chassis 1.) Resistant to cone 75mph 2.) Bump, accel, brake, corner loads: 3g/1.5g/1.5g 3.) Torsional Stiffness: 2500lb*ft/degree 4.) Weight < 55lbs

Functional Decomposition ChassisPedal BoxUndertray Inputs -Tire Contact Patch Loads -3G Bump -2G Cornering -2G Accel/Braking -Driver Ergonomics -Packaging Constraints -Driver Pedal Depression (200lbs) -Weight of Driver Legs in 3G Bump -Air Flow -Inertial Loads under 3G Bump -1.25" Ground Clearance -Abrasion with Road 50mph Outputs -Chassis Twist -Chassis Flexure -Chassis Extension -Pedal Box Deflection <.010" -Undertray Deflection -Aerodynamic downforce Functionality Chassis must withstand wide array of loading schemes. Response to loading must be limited to mild chassis deformation. Chassis failure must NOT occur as driver safety is of primary importance. Chassis must be comfortable and package all necessary components without being unnecessarily large. Pedal box must withstand loads imparted by the driver without failing. Failure can result in an unguided ballistic land missile. Excessive deflection leads to wasted driver effort and decreased braking feel. Pedal box must also be adjustable to accommodate driver heights between 5'5" and 6'5". Undertray mounts must be able to withstand loads imparted by the tray's downforce and its inertial loads under bump. Undertray must also be robust enough to be rubbed against road surfaces at 50mph without abrading through.

Concepts Generated Chassis Roll Hoop Attachment: 1.Bolted 2.Bolted and Bonded 3.Co-cured and bolted 4.Cut out/contour flange 5.Solid planar flange & move fuel cell Chassis Shape: 1.Curved panels 2.Flat, planar facet 3.Facets with slight curvature/twist

Gel-Coat/Fiberglass Mold Wood/MDF/Fiber Glass/Tooling Board Plug Concepts Generated Chassis Manufacturing Metal Template Plug (Photo: Harbor Patterns F-22 Canopy) Graphite Pre-Preg Mold (Photo: Harbor Patterns Bell Helicopter Skin Mold)

Concepts Generated Pedal Box Stiffening Scheme: 1.Flat plate w/ core under pedal box 2.Rectangular bonded inserts 3.Ribs bonded in channels Manufacturing Concepts: 1.Plastic/metal plate with milled channels 2.Solid carbon with channels milled in it 3.Pultrusion 4.Vacuum Bagging 5.Infusion 6.Compression Molding

Concepts Generated Undertray: Tunnel Shape: 1.Large Radii – Ease of Manufacturing 2.Sharp Corners – Better flow properties 3.Extend Past Rear Wheels – Better flow properties 4.Shorter than Rear Wheel Centerline – Legal, Lighter, Easier to manufacture Stiffening: 1.Stiffeners in flow 2.Add no stiffeners 3.Stiffen above tray

Concepts Generated Undertray: Jacking Point Concepts: 1.Carbon: Integrated into tray, jack up car w/ tray 2.Aluminum: Bonded onto tray, jack up car w/ tray 3.Steel: Cut out undertray, weld steel to chassis, do not jack up car w/ tray Jacking Point Regulations: 1.Must be painted orange 2.Higher than 3” off ground but below 6.9” 3.Visible from 3 feet away 4.Bottom half of tube must be exposed 5.Material: steel or aluminum