ODU Formula SAE MAE 435 Midterm Report

Formula SAE The Formula SAE competition challenges teams of university undergraduate and graduate students to conceive, design, fabricate, develop and compete with small, formula style, vehicles.

Competition Static Event Points: Dynamic Event Points: Presentation (75) Engineering Design (150) Cost Analysis (100) Dynamic Event Points: Acceleration (75) Skid-Pad (50) Autocross (150) Efficiency (100) Endurance (300)

Our Team MATTHEW SANTJER BJORN MALMFELDT CHRIS SAVEDGE MICHAEL TERLESKY ROBERT SLADE RICHARD JONAS GEORGE KOUTROS JASON LENHARDT JOHN PRESGRAVES DANIEL SMITH RYAN TETER NICHOLAS GARNER

Suspension Suspension has been designed in SolidWorks. Suspension Geometry was identified using Optimum Kinematics.

Suspension Shocks, pushrods, and rockers have been installed Camber, caster, and toe has been properly set The rockers were designed for ideal motion ratio and linear spring rate

Differential Analysis The differential has been designed and fabricated. SolidWorks analysis will be conducted on the existing design.

Intake The intake has been fabricated and installed. Currently we are analyzing different restrictors designs in SolidWorks The team will 3D print several restrictors and test on the flow bench.

The headers has been installed on the engine and leak tested. Exhaust The headers has been installed on the engine and leak tested. The firewall is being designed to insure the seat and fuel tank are not subject to heat produced by exhaust system.

Body panels are being fabricated using fiberglass. Aerodynamics Body panels are being fabricated using fiberglass. Analysis will be conducted with Fluent software to calculate maximum downforce generated by diffuser.

The calipers have been mounted to the uprights. Brakes The calipers have been mounted to the uprights. The pedals have been fabricated & installed and master cylinders mounted on the frame. Hydraulic pressure has been adjusted and a thermal analysis is being conducted on the system.

Force analysis for the pneumatic shifting system has been conducted. Control System The manual shifting lever has been fabricated and installed on the car. Force analysis for the pneumatic shifting system has been conducted. MXL Strada is awaiting purchase and will be electrically mated with ECU upon arrival.

Analysis has been conducted on each pedal using SolidWorks Pedal Assembly The pedal setup is a three pedal assembly with a clutch, brake, gas arrangement. Analysis has been conducted on each pedal using SolidWorks

Progress - Chassis Design The chassis design and fabrication has been completed. Our team started by fabricated the current table to be level in all planes and mounting holding brackets for the front, console, driver, and rear hoops. The structural members have been fabricated using hollow 4130 steel using the following types: 1”x1”x0.049” Square 1”x0.095” Round 1”x0.065” Round 1”x0.049” Round

Progress - Parts Metal Concepts Inc. has fabricated parts for the pedals, differential, intake, and suspension.

Progress - Steering The steering rack has been aligned in plane with uprights for smooth wheel movement. The steering rods have been fabricated and connected to the steering knuckles on the uprights. The steering wheel has been located and mounted for best possible driver ergonomics.

Progress - Uprights The uprights have been designed, fabricated and installed. The upper and lower A-Arms and steering have been connected and tested.

Questions?