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

Final Customer Needs Composite Monocoque –Torsionally Stiff –Lightweight –Ergonomic –Easily obtain complex contours –High precision suspension points –Test data for correlation Composite Pedal Box –Stiff –Comfortable –Lightweight –Adjustable –Strong –Easy/quick to manufacture Composite Aero Package –Make downforce with minimal weight gain –Center of pressure below car CG –Easily manufactured –Easily mounted/dismounted from chassis

Engineering Specifications Pedal Box Tube center-to-center distance = 11.2in 1in O.D. tubing 2g bump loading, 1.5g braking load Pedal load = 200lb Must accommodate 3-pedal layout Master cylinders Bias bar Adjustable Manufacture time = < 12 hours Weight: < 1.5lb Undertray Lift: 25mph Weight: < 25lb Must mount to chassis and not interfere with suspension geometry. Chassis Weight < 55lbs Resistant to cone 75mph Bump, accel, brake, corner loads: 3g/1.5g/1.5g Production time: 14 weeks Torsional Stiffness: 2500lb*ft/degree Wheelbase/Fr Track/Rear Track Width: 63”/50”/48”

Benchmarks Pedal Box RIT FSAE Team F-16 Material: 2024 Aluminum Material Cost: $255 (est., McMaster-Carr) Machining Time: 12 hours Deflection: 0.009in (200lb driver input) Weight: 1.5lb (frame + clutch/brake tabs) Swinburne FSAE Team TS06 Material: 7075 T651 Aluminum Material Cost: $265 (est., McMaster-Carr) Machining Time: 15 hours (est.) Deflection: 0.004in (220lb driver input) Weight: 1.76lb (frame) Undertray TU Graz TANKIA 2007 Lift: 25mph Weight: 20lb Chassis RIT FSAE Team F-15 Material: 4130 Fabrication Time: 15 Weeks Torsional Stiffness: 900lb*ft/degree Weight: 456lbs (vehicle) 74lbs (chassis) RIT FSAE Team F-16 Material: 4130 Steel Machining Time: 13 Weeks Torsional Stiffness: 600lb*ft/degree Weight: 426lbs (vehicle) 65lbs (chassis) TU Munich Material: Carbon Fiber Torsional Stiffness: 4300lb*ft/degree

Concept Generation Pedal Box Undertray Chassis

Plan for 12/12 Ryan BaldiSource material and machining facility for plugs. Dave HollandObtain rough material properties. Obtain rough chassis model. Begin work in ANSYS. Aid with bell crank mounting concepts. Martin IwanowiczResearch rules compliance. Obtain loads for chassis from rigid body kinematics. Ted KusnierzFinalize pedal box geometry and start analysis. Anthony SalvoDevelop undertray geometry and start analysis. Charles ThomasContinue development of chassis geometry. Generate concept for front roll hoop mounting and bell crank mounts