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Design and Optimization of a Formula SAE Vehicle

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Design and Optimization of a Formula SAE Vehicle Design and Optimization of a Formula SAE Vehicle A Major Qualifying Project Submitted to the Faculty of Worcester Polytechnic Institute In partial fulfillment of the requirements for the Degree in Bachelor of Science In Mechanical Engineering By: William Kinkead, ME Connor Morette, ME Adrian Pickering, ME Zachary Sears, ME James Waldo, ME Date: _____________ Approved By: Professor David C. Planchard, ME Advisor Abstract The purpose of the Society of Automotive Engineers (SAE) Formula Major Qualifying Project (MQP) is to develop a vehicle for entry in competitions. This MQP went beyond textbook theory by designing, building and testing the performance of a real vehicle. Students worked in multidisciplinary (Mechanical, Electrical, Computer Science, Manufacturing and Aero) teams thought out the year. Emphasis was placed on reliability, serviceability, and adjustability of critical sub-systems. Suspension, steering and drivetrain components are designed to be easily replaceable on the track with only basic tools. The engine was paired with a custom pneumatic shift transmission to allow an automatic shift mode to make fast, consistent shifts. An aerodynamic package is designed to provide maximum downforce in the expected speed range, without creating large amounts of drag. Sensors are strategically located on the aerodynamic, suspension and drivetrain components for faster and more accurate collection of data used in tuning the vehicle. A removable steering wheel integrated drivetrain feedback, vehicle controls, and a manual paddle shift mode to provide comfortable and intuitive driver controls. The vehicle is required to accommodate a 95th percentile model comfortably and safely in the driver's compartment. The design of the interior driver compartment and bodywork allows the driver to quickly and safely exit the vehicle in an emergency situation, while protecting them from road debris and providing an aesthetically appealing bodywork package. 1 Acknowledgments This project team would like to acknowledge the following people for their assistance and support throughout this project: Professor David Planchard Professor Yagoobi Professor Sullivan Professor Hall Barbara Furhman Kevin Arruda Mikhail Tan Professor Stafford Washburn Shops Peter Hefti 2 Table of Contents Design and Optimization of a Formula SAE Vehicle ............................................................................... 0 Abstract ................................................................................................................................................... 1 Acknowledgments ................................................................................................................................... 2 Table of Contents .................................................................................................................................... 3 List of Figures ......................................................................................................................................... 8 List of Tables ........................................................................................................................................ 15 List of Equations ................................................................................................................................... 16 Introduction ........................................................................................................................................... 17 Frame .................................................................................................................................................... 18 Ergonomics ........................................................................................................................................... 21 Introduction ....................................................................................................................................... 21 Seat Pan ............................................................................................................................................ 21 Pedal Assembly ................................................................................................................................. 23 Head Rest .......................................................................................................................................... 26 Seat Insert ......................................................................................................................................... 29 Suspension ............................................................................................................................................ 31 Background ....................................................................................................................................... 31 Design Parameters ............................................................................................................................. 31 A-Arm Design ................................................................................................................................... 33 Design Basics ................................................................................................................................ 33 Adjustment Range and Revision .................................................................................................... 33 A-Arms design for manufacture ..................................................................................................... 34 3 A-Arm welding process ................................................................................................................. 34 Tab Design ........................................................................................................................................ 37 Tab Manufacturing ........................................................................................................................ 39 Welding ......................................................................................................................................... 41 Rocker Design ................................................................................................................................... 43 Rocker conceptual design .............................................................................................................. 43 Tab design ..................................................................................................................................... 45 Transmission angle analysis ........................................................................................................... 45 Initial shock geometry.................................................................................................................... 52 Revision 1 ..................................................................................................................................... 53 Revision 2 ..................................................................................................................................... 58 Upright Design .................................................................................................................................. 61 Kinematic Design and Structure ..................................................................................................... 61 Full wheel assembly....................................................................................................................... 62 FEA and material ........................................................................................................................... 64 Rear Upright Manufacturing .......................................................................................................... 67 Front Upright Manufacturing ......................................................................................................... 69 Hub Design ....................................................................................................................................... 71 General .......................................................................................................................................... 71 Packaging driven for optimization .................................................................................................. 71 Design for Manufacture ................................................................................................................. 73 FEA for worst case ........................................................................................................................ 76 Steering ................................................................................................................................................. 81 Design Parameters ............................................................................................................................. 81 4 Design ............................................................................................................................................... 83 Geometric Constraints and Packaging ............................................................................................ 83 Optimization for low steering effort on the autocross and endurance track ...................................... 83 System Goals and Final Specifications ........................................................................................... 83
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