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And Rear Driveline Package for Formula SAE

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And Rear Driveline Package for Formula SAE Lightweight Torsen Style Limited Slip Differential and Rear Driveline Package for Formula SAE by Tony Scelfo SUBMITTED TO THE DEPARTMENT OF MECHANICAL ENGINEERING IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE DEGREE OF BACHELOR OF SCIENCE AT THE MASSACHUSETTS INSTITUTE OF TECHNOLOGY JUNE 2006 C2006 Tony Scelfo. All Rights Reserved. The author hereby grants to MIT permission to reproduce and to distribute publicly paper and electronic MASSACHUt'i'Fl-. I I'ITUTE copies of this thesis document in whole or in part Or 'r.. v,, in any medium now known or hereafter created. AU 0 2 2006 /, // LIBRARIES Signature of Author 4::epx ep ,tof Mechanical Engineering May 12, 2006 Certified by I 1// ' ) J ?Daniel Frey Professor of Mechanical Engineering Thesis Supervisor Accepted by _ i__ _l.__ __ John H. Lienhard V KCj I . rossor of Mechanical Engineering Chairman, Undergraduate Thesis Committee ARCHIVES Table of Contents ABSTRACT......................................................................................................................... 7 I FSAE Competition ........................................................................................................... 9 2 Overall Design Philosophy........................................ 10 2.1 Functional Requirements....................................................................................... 10 2.2 Manufacturing Concerns ........................................ 11 2.3 Integration .............................................................................................................. 11 2.4 Total Package......................................................................................................... 11 3 M echanical Design ......................................................................................................... 12 3.1 M ounting brackets.................................................................................................. 12 3.1.1 Bracket concept........................................ 12 3.1.2 Bearing Selection........................................ 13 3.1.3 Chain Tensioning........................................ 14 3.1.4 M aterial Selection........................................................................................... 14 3.1.5 Manufacturing and Assembly Considerations........................................ 15 3.1.6 Estimation of Reaction Forces ........................................................................ 15 3.1.7 FEA of Differential Brackets ........................................ 16 3.2 Differential Center Section........................................ 18 3.2.1 Differential Center Section Concept .............................................................. 18 3.2.2 Material Selection........................................ 19 3.2.3 Bearing and Seal Selection........................................ 20 3.2.4 Manufacturing and Assembly Considerations......................................... 20 3.2.4.1 Picture of Assembly......................................... 20 3.2.4.2 Journal pin retention............................................................................... 21 3.2.4.3 Thrust washers for element gears........................................................... 21 3.2.4.4 Case sealing: o-rings and sealing sleeve ......................................... 22 3.2.5 Estimation of Reaction Forces ......................................... 23 3.2.6 FEA of Differential Center Section ................................................................23 3.3 CV Joints and Axles ........................................ 24 3.4 Rear Hubs......................................... 25 3.4.1 Hub Concept. ....................................... ............................................ 25 3.4.2 M aterial Selection......................................... 26 3.4.3 Bearing Selection......................................... 26 3.4.4 Manufacturing and Assembly Considerations......................................... 26 3.5 Drive Components........................................ 27 3.5.1 Component Concept........................................ 27 3.5. 1.1 Sprocket ........................................ 27 3.5.1.2 Input Bell........................................ 27 3.5.1.3 Chain........................................ 28 3.5.2 Manufacturing and Assembly Considerations......................................... 28 3.6 Bolts, Nuts and other Hardware ........................................ 29 4 M anufacturing .................................................................................................... 29 4.1 M ounting Brackets........................................ 29 3 4.2 Differential Center Section .................................................................................... 30 4.3 Rear Hubs .................................... 36 5 Testing ................................. 38 6 Conclusion ..................................................................................................................... 39 7 References .............................. 40 8 Suppliers ........................................................................................................................ 41 9 Acknowledgments......................... 42 4 Illustration Index Illustration 1: Differential Total Package.......................................................................... 11 Illustration 2: Bracket Concept.............................................................. 12 Illustration 3: Left Bracket FEA Forces and Restraints ..................................................... 16 Illustration 4: Left Bracket FEA Results.............................................................. 16 Illustration 5: Right Bracket FEA Forces and Restraints................................................... 17 Illustration 6: Right Bracket FEA Results.............................................................. 17 Illustration 7: Completed Differential Center Section....................................................... 18 Illustration 8: Assembly of Differential Center Section ................................. 21 Illustration 9: Differential Center Section FEA Forces and Restraints..............................23 Illustration 10: Differential Center Section FEA Results. ................................ 24 Illustration I1 : Rear Hub Assembly .............................................................. 25 Illustration 12: Differential Bracket EZ-Trak Beginning.................................................. 29 Illustration 13: Differential Bracket EZ-Trak Bearing Pocket. ................................. 30 Illustration 14: Humble Beginning.............................................................. 31 Illustration 15: Drilling a Center Hole .............................................................. 31 Illustration 16: Checking Alignment in EZ-Track............................................................. 32 Illustration 17: Cutting Element Gear Windows.............................................................. 32 Illustration 18: Cleaning Inside Face .............................................................. 33 Illustration 19: Installing Helicoils on Input Face ............................................................. 33 Illustration 20: Completed Center Section with Torsen Internals Shown Next to Stock H ousing............................................................................................................................... 34 Illustration 21: Inserting Friction Plate and Side Gears..................................................... 35 Illustration 22: Timing Marks on Element Gears .............................................................. 35 Illustration 23: Installing Element Gears and Thrust Washers. ................................ 36 Illustration 24: Setup for Drilling and Reaming Bolt/Pin Pattern...................................... 37 Illustration 25: Cutting Bolt Head Pattern .............................................................. 37 5 6 Lightweight Torsen Style Limited Slip Differential and Rear Driveline Package for Formula SAE by Tony Scelfo Submitted to the Department of Mechanical Engineering on May 12, 2006 in Partial Fulfillment of the Requirements for the Degree of Bachelor of Science in Mechanical Engineering ABSTRACT This document describes the design and fabrication of a complete driveline package for the MIT Formula SAE race car. The driveline is centered around a custom aluminum housing for a Torsen® T 1Igearing. This gearing provides a torque biases limited slip differential which has had good success in the Formula SAE series. The design includes all of the components needed to deliver power from a Honda CBR600 F4i engine to the wheels of a custom race car. This document is intended to document the design process that went into the 2006 MIT FSAE car. Furthermore, this document describes many of the steps required to manufacture each component. FSAE competitors often face the challenge of fabricating the parts that they design. Manufacturing setups are shown and described in order to help designers best prepare for fabrication. Thesis Supervisor: Daniel Frey Title: Professor of Mechanical Engineering TORSEN® is a registered trademark of Toyoda-Koki Automotive Torsen North America Inc. 7 8 1 FSAE Competition Formula SAE® is a competition for university undergraduate and graduate students. Teams that compete must design, fabricate and compete with small, formula style auto cross cars. Teams typically spend between eight and twelve months
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